CEMAS elettra - Your partner in plastic joining

Staking at the speed of light

An alternative to ultrasonic

The InfraStake infrared staking process is a ground-breaking type of non-contact plastic staking, which can be considered an alternative to the ultrasonic staking technology.

This low-impact process, designed and patented, owes its success to the wide variety of (its) potential applications, ranging from highly sensitive PCB assemblies and delicate medical devices to large automotive interior trim components and LED lighting.

Plastic staking is a method of joining components together that uses a molded stud or boss to mechanically retain a mating component. Heat is applied to the boss, softening it. A forming tool is then used to reshape the material into a cap or stake.

Through the use of infrared light as the energy source and the ability to control the environment around the plastic boss, the InfraStake process is an effective alternative to the conventional staking technologies.
  • IS32

    The Latest

    • Analog punch position sensing (+/- 0.05 mm)
    • 100 W tungsten halogen lamp
    • 32 mm diameter module
    • Max boss size: Ø9.0 x 12.7 mm
    Boss type Solid-round Hollow-round Rectangular
    Max height* 12.7 mm 12.7 mm 8 mm
    Max diameter* 5.5 mm 9.0 mm -
    Max thickness* - - 3 mm
    Max length* - - 10 mm
  • IS125

    The Original

    • Digital punch position sensing (+/- 0.5 mm)
    • 100 W tungsten halogen lamp
    • 32 mm diameter module
    • Max boss size: Ø6.4 x 9.5 mm
    Boss type Solid-round Hollow-round Rectangular
    Max height* 9.5 mm 9.5 mm 8 mm
    Max diameter* 4 mm 6.4 mm -
    Max thickness* - - 3 mm
    Max length* - - 10 mm
  • ISM200

    The Smallest

    • Digital punch position sensing (+/- 0.5 mm)
    • 35 W tungsten halogen lamp
    • 20 mm diameter module
    • Max boss size: Ø3.0 x 4.0 mm
    Boss type Solid-round Hollow-round Rectangular
    Max height* 4 mm 4 mm 4 mm
    Max diameter* 3 mm 4 mm -
    Max thickness* - - 2.5 mm
    Max length* - - 4 mm
* Dimensions outside of these maximum recommendations are available. Ask us.
  • Couple IS32 with our new InfraStake software.
  • Reduces lifetime cost by reducing maintenance.
  • Provides full quality assurance through increased process monitoring.
  • Reduces issues in manufacturing with a more intuitive process.

Equipment options

We offer 'turn-key' machines ranging from standard Extol press options to fully customized assembly machinery. Additionally, Extol provides a comprehensive package of InfraStake components and accessories to customers who build assembly equipment 'in-house' and to equipment integrators/machine builders.
  • Custom Machines

    The possibilities are endless with CEMAS' custom machines. We've built unique single-point InfraStake machines and others incorporating 100+ InfraStake modules. Projects range from simple bench-top machines to complex work cells, which feature numerous IR machines and additional joining processes and functions.
  • Integration Packages

    Integration packages include:
    • InfraStake modules;
    • power supply / controller;
    • air manifolds for module function;
    • dual flow rate air filtration and regulation system;
    • maintenance tool kit;
    • detailed documentation.

Why buy an infrastake module

clear and irrefutable strong points

  • Tight stake joints

    InfraStake modules are designed to clamp the components during the staking process. Each module clamps directly at each stake point with independent pressure to ensure the assembly is tight when the staking process is complete. A tight joint means no buzzing, squeaking, or rattling!
  • Quality assurance through process monitoring

    InfraStake software monitors several key process variables to ensure a successful and quality stake joint. Current sensors ensure the IR energy turns on while position sensors monitor the punch to detect the proper height of the boss and depth of the completed stake.
  • No A-surface marking

    InfraStake does not use excessive heat or vibrate, which greatly reduces the risk of A-surface marking.
  • Higher quality and lower energy than hot air

    InfraStake produces stronger, more consistent stakes and uses less air and electricity than the hot air staking process.
  • Lower cost than ultrasonics

    InfraStake is more cost effective than ultrasonic staking. The power supplies used with InfraStake are much less expensive than ultrasonic generators and each one powers up to four modules.
  • Safe, non-invasive staking

    InfraStake does not vibrate during the staking process and the module does not get hot because the IR energy is focused only on the plastic boss. This means that it is safe to use with sensitive electronic components.
  • Strong

    InfraStake heats up the plastic boss to a semi-molten state before staking. This allows the material to flow when it is formed and reduces any internal stresses that can occur with other processes.
  • Reliable and repeatable

    InfraStake uses IR energy from a halogen lamp as the heat source. The output from this lamp is consistent and controlled by time which means the amount of energy applied to the plastic boss is the same every cycle.
  • Highly customizable
  • No compromise for quality
  • Easy maintenance
  • Ergonomic loading station
  • Reliability
  • Energy saving technology
  • Innovative and user friendly UI
Cutting edge technology and fully equipped machines as standard. Discover more
  • Highly customizable

    Many standard features included in our machines are optionals for competitors and, should this not be enough, just turn the page to discover a full range of over 60 optionals for your tailor-made machines.
  • No compromise for quality

    All components used by CEMAS are from world leading suppliers and never sub-brands.
    Safety is our ultimate goal, as well as a prompt availability of spares worldwide.
  • Easy maintenance

    The use of the latest-generation electronic components has resulted in a remarkably smaller control panel, and in positioning the hydraulic unit below the control panel for the 240 Hz machines. This change has totally cleared an inner compartment and has made tooling maintenance and set up operations easier.
  • Ergonomic loading station

    Special care was devoted to the manual loading steps of the process, both for small and large machines: to minimize effort on the backbone, the loading/unloading area was kept as close as possible to operator. There are no machines of the same class available on the market where this distance is so small.
  • Reliability

    Light curtains are fitted as a standard to ensure maximum operator safety, further to decreasing the total cycle time of each welding. Light curtains are integrated to protect them against collisions and as a result of an extremely accurate and well defined design.
  • Energy saving technology

    Big welding area and low power required: this is energetic efficiency!
  • Innovative operator interface system

    Accurate does not mean complicated: no other machine on the market is so "user friendly".
    We have made a big effort in designing our video graphic to simplify any operation. Actually, there would be no need for operator's training.
    • Switching to your language is as simple as pressing a key.
    • Parameters can be set to include up to 8 different welding steps.
    • Tool movement graphic programming: no need to call us for a new tool!
    • Monitoring of the "just in time" process by displaying welding diagrams.
    • Constantly linked to CEMAS through the Teleservice system for diagnostics and customer's service on line.

DESIGN GUIDELINES

BOSS SIZES

The InfraStake process can be used to stake bosses of many different sizes. The IS125 model, which is the most popular size, is 32 mm in diameter at the concentrator. Due to recent design improvements, it can now stake bosses up to 8 mm in diameter and up to 12 mm tall. There is one other standard module, the ISM20 module, for small bosses in small areas. The typical boss sizes can produce very strong stakes. In a group of ten 6 mm diameter, hollow, round, polypropylene bosses, the average break strength was 117 pounds per stake. In every case, the boss failed at the base, not at the stake. This type of failure mode indicates that the strength of the joint is limited not by the formed stake, but by the tensile strength of the cross section of the plastic boss.

STAKING TYPES and BOSS DESIGN

Dome


  • The recommended clearance hole diameter is 1.1D (1.25 is the maximum diameter)
  • The maximum recommended boss height above the mating surface is 1.5D
  • These guidelines apply to bosses up to 3.30 mm in diameter

Rosette


  • The recommended clearance hole diameter is 1.10 (1.25 is the maximum diameter)
  • The maximum recommended boss height above the mating surface is 1.5
  • These guidelines apply to bosses up to 7.62 mm in diameter

Elongated dome


Please consult the Applications lab for recommendations on through-hole clearances and boss height above the mating

BOSS ANGLES


CleaningReplacing the lamp

EVERY 3 WEEKS

How often do the reflective surfaces need to be cleaned?
Every three weeks is a good starting point for a PM schedule for a single-shift, 5-day operation.
The interval can then be adjusted as necessary. Inspect the insides of the reflectors and concentrators every 3 weeks and look for dirty residue. Another indicator of dirty reflective surfaces is a boss that isn't fully staked by process settings that were working well before.

1. Disassemble the module

Press the snap button and remove the concentrator and reflector.

2. Clean the reflective surfaces

Thoroughly clean the reflector and concentrator with a soft, clean cloth and non-abrasive polish (i.e. Award Glo) or any non-abrasive cleaner (i.e. window cleaner or isopropyl alcohol). Extol offers a cleaning kit that contains Award Glo polish and a polishing cloth. Part No. 1102706

3. Reassemble the module

Place the reflector into the concentrator according to the position markers and reinstall into the module.

EVERY 1000 HOURS

How long should the lamp last?
The tungsten-halogen lamp in the IS32 model InfraStake module should last approximately 1000 hours. This varies somewhat from lamp to lamp, but generally speaking, if your InfraStake heat time is 6 seconds, the lamp should last for half a million cycles.

1. Disassemble the module

Press the snap button and remove the concentrator and reflector.

2. Remove Punch and Lamp Assembly

a) Firmly grasp the punch and pull until it releases from the magnet.
b) Remove the lamp assembly from the punch.

Caution: Lamp may be hot!

3. Remove Lamp

Pull the lamp out of the lamp holder. Discard old lamp.

Caution: Lamp may be hot!

4. Replace Lamp

Using gloves or the packaging around the lamp, push the new lamp into the lamp holder. Discard packaging.

Note: Do NOT touch the lamp with your fingers as oil from your skin may reduce lamp life.

5. Reassemble the module

Place the lamp assembly into the punch. Slide the punch into the module until it snaps to the magnet. Place the reflector into the concentrator according to the position markers and reinstall into the module.

6. Reset the lamp on-time and cycle counter

On the HMI, under the Monitor section, open the Maintenance tab. Reset the lamp on-time and cycle counter back to zero in order to track the usage of the new lamp. A confirmation prompt will appear, tap OK to confirm and reset the lamp.