Global technology and engineering company Emerson reports that it has developed new heat-staking technology that will give manufacturers greater design freedom. In particular, it will facilitate the joining of complex, delicate, and sensitive components to plastic moldings.

The Branson GPX platform from Emerson uses a pulse method that optimizes the heat-staking process to produce high-quality joins, superior product aesthetics, and energy savings in increasingly challenging applications, said the company in a press release.

Electronics, automotive, and medical device manufacturers must produce more creative designs to meet rapidly changing market demand, said Emerson in the release. This has led to an increase in challenging heat-staking applications involving parts with more complex 3D geometries, closely aligned features, and fragile or heat-sensitive components, such as soldered components or sensors. A greater number of blended, glass-reinforced, chromed, and metalized plastics also are being used.

The Branson GPX platform’s PulseStaker technology provides instantaneous heating and cooling, with adjustable cycle times for optimized, low-energy heat staking. The process creates no particulates or burn marks, and enables more delicate and sensitive parts, such as those with embedded electronics, to be joined with consistently high-performance finishes, according to Emerson.

The technology is suitable for all heat-staking applications, including those involving thermoplastic materials or metalized, coated parts. A range of heat-staking tip designs are available that can be adapted to meet any requirement. Multiple points can be staked simultaneously, providing manufacturers with greater design freedom.

“The automotive, electronics, and medical industries require more complex, delicate, and sensitive components to be joined to plastic moldings,” said Priyank Kishor, Global Product Manager for Branson Products at Emerson’s Automation Solutions business. “The unique heat-staking process that the Branson GPX platform provides helps to meet this demand and offers manufacturers a broad range of benefits, such as superior product aesthetics and reduced energy use.”