When it comes to manufacturing for regulated industries like medical devices, automotive systems, and electronics, the stakes are high – and so are the standards. Heat staking is a proven and precise method for thermoplastic assembly, and at Thermal Press International (TPI), we specialize in delivering cleanroom-ready heat staking systems tailored for the most demanding applications.
From advanced wearable devices to microfluidic diagnostics and catheter assemblies, our customers rely on TPI equipment for repeatable, traceable, and compliant bonding solutions.
Medical Devices: High Precision in Highly Regulated Environments
In the medical industry, even the smallest plastic post or connection point can be mission critical. That’s why heat staking is such a valuable process – it enables permanent, particulate-free bonding between plastic and non-plastic components without the need for adhesives or solvents.
Examples of medical applications using TPI heat staking equipment:
These assemblies often require:
- Extremely small and fragile plastic features
- High bond strength and dimensional consistency
- Cleanroom compliance (FDA or ISO 13485)
- Precise temperature, time, and pressure control
- OPC data capture for process traceability and validation
Automotive & Electronics: Performance Under Pressure
In the automotive and electronics industries, our customers are heat staking:
- LED modules and optical housings
- PCBs and flex circuits into ruggedized enclosures
- Wire guides and fasteners to molded dashboards or assemblies
These industries also demand:
- Consistent thermal profiles across high-volume runs
- Custom multi-head tooling for staking multiple points and assemblies at once
- Integration into conveyor lines or robotic cells for scalable production
What TPI Provides to Regulated Manufacturers
TPI is more than a machine supplier – we’re a solutions partner for complex thermoplastic assembly challenges.
Our customer benefit from:
Custom Tooling & Modular System Design
- Tailored nests, stripper plates, and thermal heads for each application
- Options for pneumatic or servo-driven heads
- Multi-head arrays for staking multiple parts simultaneously to maximize throughput and maintain uniform thermal performance
TPI’s in-house fixture design expertise plays a critical role in supporting high-efficiency production. Whether a customer is staking a single component with multiple posts or running several identical parts per cycle, our custom nests and tooling are engineered for precise alignment, thermal consistency, and repeatable results. Fixturing solutions can be designed to accommodate complex part geometries, ultra-small features, or cleanroom requirement – all while minimizing changeover time and maximizing productivity.
Automation & Line Integration
- Multi-Workstation Thermal Press Systems for work cells
- SMEMA-compatible Inline Conveyor Presses for automated line integration
- Flexible configurations to suit high-mix, high-volume operations
Cleanroom-Ready and Compliant Designs
- Designed to meet FDA and ISO cleanroom standards
- Optional air extraction ports, safety curtains, and exhaust control
- Support for OPC-UA connectivity and data logging for validation
Advanced Process Control
- Sophisticated HMI with recipe management, digital calibration, and thermal tuning
- Tight tolerances for temperature, dwell time, and force
- User-level controls for secure, validated operation
Why It Matters
In regulated industries, it’s not enough for a plastic joint to simply “hold.” It must meet performance specs, withstand environmental stress, and be validated to regulatory standards – often down to the individual cycle level. That’s where heat staking, and TPI’s equipment, stands out.
With decades of experience in medical, automotive, and electronics applications, we understand what it takes to design and deliver heat staking systems that go beyond general purpose performance.
Ready to Discuss Your Project?
If your team is working on a medical or industrial product that demands high-precision thermoplastic assembly, we’d love to help. Reach out to learn more about how TPI can support your production goals – from initial prototyping to full-scale automation.
Explore our heat staking applications: Heat Staking Solutions | Thermal Press | 925-454-9800
Contact our team for a consultation: Contact Thermal Press | Heat Staking & Heat Sealing Solutions | 925-454-9800