IR End Cap Welding System

At Thermal Innovations Corp., we are able to bring together state-of-the-art technology and quality engineering to develop custom thermal processing systems. Whether building a cost-effective modular system or designing a from the ground up custom project, we can always provide a comprehensive solution that captures every nuanced requirement of your manufacturing or treating process. Furthermore, our expertise in multiple types of heating systems ensures that we are best suited to delivering performance and efficiency in one package.

We recently assisted a filter manufacturer primarily working with plastic end cap materials. Their manufacturing workflow requires attaching plastic endcaps to pleated paper filter media with a strong, durable seal. Since welding heat must be localized to the cap itself, the customer was not able to find an off-the-shelf solution for improving weld quality and cycle time. They came to us directly because of our prior work on developing custom systems.

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Filter Cartridge and End Cap Prior to IR Welding

IR End Cap Heating Prior to Welding

Completed IR Welded Filter Assembly

Based on their product specifications and application directives, we designed and built a custom plastic welder for their filter product. This system, capable of capping two filters at once, clamps the filter and end cap and uses a non-contact electric infrared heater that applies heat to the specific dimensions and areas that need to be welded. Largely automated, our custom system requires no interaction beyond loading and unloading of filter units. Our system provided a stronger, and more consistent weld while still significantly improving cycle times and even personnel safety.

We continue to deliver smartly engineered, effective, and cost-conscious solutions for thermal treatment processes and procedures. Whether you’re a small-scale customer looking for a great way to upgrade production, or a heavy industry facility in desperate need of faster, more consistent thermal treatments, we will be able to meet your needs exactly.

For more information about our capabilities, portfolio of work or current technology offerings, feel free to contact us directly. end caps.

Additional Information

Industry Focus

Automotive Electronics Furniture: Heating Equipment OEM
Heavy Equipment

Marquee Customers

Automotive Industry

General Motors Corporation 7 Plant Locations Fiat-Chrysler Mitsubishi/Diamond Star BMW

Toyota
Ford Motor Company
- 2 Plant Locations
Volvo
- 3 Plant Locations

Electronics Market

Fiat-Chrysler Motorola Delphi-Delmex United Technology TRW Automotive TE Connectivity

Jabil
Donaldson
Parker Finite Division
PolyFlex Circuits
LCR Electronics
Senerject

General Industrial & Heavy Equipment

Caterpillar Steelcase Haworth Harley Davidson Corporation Knoll Group Maytag Corporation Macdon Industries Fiat-Chrysler Copeland Dupont Powder Coatings Valspar Electric Boat Division of General Dynamics Sauder Woodworking

Tyler Refrigeration
Jerith Manufacturing
TruVue
Cosco
General Electric Company
Siemens
Ingersoll Rand Company
3M
Dant-Clayton
Lear Corporation
Kentucky Manufacturing
Springco
Thomson Industries

Industry Standards: CCAI (Chemical Coaters Association International)
PCI (Powder Coating Institute)
SME

File Formats: AutoCAD
SolidWorks

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