Secondary Operations
Secondary Operations for Injection-Molded Components
Whether your injection-molded part is large or small, simple or complex, Gemini Group has what it takes to get the job done. We specialize in a variety of techniques used for plastic welding, riveting and staking, and assembly to complement our injection molding processes. Keeping your component under one roof will help eliminate shipping costs, decrease lead-times, and enhance accountability.
If your component is more than a simple shoot and ship, then we should talk.
Ultrasonic Plastic Welding
Ultrasonic plastic welding involves converting high frequency energy into a mechanical motion (vibration) to create frictional heat in a focused area. The heat generated melts the plastic forming a molecular bond. This technique can be used for welding plastic to plastic, plastic to vinyl, and plastic to metal.
Benefits of Ultrasonic Plastic Welding
- Flexible and versatile with little tooling changeover or fixture modifications
- Consistent and repeatable
- Very rapid weld time confined to the bonding or joint area
- Can replace fasteners and adhesives
Infrared Plastic Welding
A fairly new technique used for welding plastic is infrared plastic welding. This welding technique is typically used for large part assemblies with high strength and hermetic requirements. The process utilizes a controlled infrared light emitter which welds plastic assemblies by melting the joining surfaces which are then joined together and re-solidified under pressure.
Benefits of Infrared Plastic Welding
- Fast changeover
- No part or tooling contamination
- Reduced amount of flash
Hot Plate Plastic Welding
Hot plate plastic welding is another process which can be used for large part assemblies. Heat is applied to the joint areas of parts for a predetermined amount of time, the parts are then removed from the heat source, and finally brought together and allowed to solidify under pressure.
Benefits of Hot Plate Plastic Welding
- Compatible with most thermoplastics
- Ability to weld large parts and complex shapes
- Strong sealing method
Additional Injection Molding Operations
- Insert/Over Molding
- Heat Staking
- Riveting
- Sub-Assembly
- Hot Stamping
- Foam and Acoustic Pad Assembly
- Part Identification Marking
- Parts Kitting