--- title: "How Heat Staking with Induction Works" description: "Ambrell's engineering expertise in developing induction heat staking (metal-to-plastic insertion, plastic reflow) solutions has been applied by manufacturers worldwide. " type: article version: 1 version_id: "07282c87-cffe-4f55-991e-4a157d74a892" generated_at: "2026-07-20T11:27:18.790Z" language: en-us reading_time: "13 min" word_count: 2408 keywords: ["How Heat Staking with Induction Works", "heat staking Application Notes"] url: "https://www.ambrell.com/induction-heating-applications/heat-staking" --- # How Heat Staking with Induction Works > Ambrell's engineering expertise in developing induction heat staking (metal-to-plastic insertion, plastic reflow) solutions has been applied by manufacturers worldwide. ## Key Takeaways - How does induction heat staking work? - Benefits of Using Induction for Heat Staking - heat staking Application Notes - heat staking Resources - 10 Induction Heating Application Notes ## Contents - [How does induction heat staking work?](#how-does-induction-heat-staking-work) - [Benefits of Using Induction for Heat Staking](#benefits-of-using-induction-for-heat-staking) - [heat staking Application Notes](#heat-staking-application-notes) - [heat staking Resources](#heat-staking-resources) - [10 Induction Heating Application Notes](#10-induction-heating-application-notes) - [10 Automotive Application Notes](#10-automotive-application-notes) - [Our Systems for heat staking with Induction](#our-systems-for-heat-staking-with-induction) # Induction Heat Staking & Reflow - [Home](https://www.ambrell.com) - [How It's Used](https://www.ambrell.com/induction-heating-applications) - Heat Staking ## How does induction heat staking work? Sometimes called thermal staking (or plastic reflow,  indirect heating) is a process by which a metallic insert is heated and pressed into a plastic material which has been drilled with a hole that is slightly smaller than the insert, resulting in an interference fit as the plastic melts and reflows around the insert. Induction generates an electromagnetic field in a work coil that induces currents in the conductive material of a workpiece placed within or near the coil. Friction from these currents elevates the temperature of the workpieces to be inserted. [Can we help?](https://www.ambrell.com/contact-us-request-process?lead_origin=heat%20staking&linked_from=Heat%20Staking%20[EN]&appnote_title=none) ## Benefits of Using Induction for Heat Staking Induction heating delivers precise, consistent heating results to meet tight production tolerances. Our non-contact induction staking solutions provide targeted, localized heating without open flame. Since induction heats only the metal inserts, the process is efficient and repeatable. [](https://www.ambrell.com/induction-heating-videos/metal-plastic-insertion-of-brass-inserts-with-induction) * * * ## heat staking Application Notes Select from our collection of heat staking notes, developed over 40 years supporting our customers. Read how we helped to solve their process heating challenges! [Heat Staking Square-wire Spring in a Wire Nut](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heat-staking-square-wire-spring-in-a-wire-nut&appnote_title=Heat%20Staking%20Square-wire%20Spring%20in%20a%20Wire%20Nut&meta_desc=To%20heat%20stake%20a%20square-wire%20spring%20within%20a%20thermoplastic%20shell&row_id=208709439573&table_id=125276734&linked_from=&referred_by=&a_b_version=) To heat stake a square-wire spring within a thermoplastic shell [Heating a Steel Pin for Fan Insertion](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-a-steel-pin-for-fan-insertion&appnote_title=Heating%20a%20Steel%20Pin%20for%20Fan%20Insertion&meta_desc=An%20EASYHEAT%20and%20its%20workhead%20require%20a%20minimal%20footprint,%20saving%20the%20client%20valuable%20floor%20space%20compared%20to%20heating%20alternatives&row_id=192891121814&table_id=125276734&linked_from=&referred_by=&a_b_version=) An EASYHEAT and its workhead require a minimal footprint, saving the client valuable floor space compared to heating alternatives [Heating Steel Inserts for Metal-to-Plastic Insertion](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-steel-inserts-for-metal-to-plastic-insertion&appnote_title=Heating%20Steel%20Inserts%20for%20Metal-to-Plastic%20Insertion&meta_desc=It%20took%205%20seconds%20with%20a%202%20kW%20EASYHEAT%20to%20reach%20temperature,%20which%20melted%20the%20plastic%20for%20a%20solid%20bond%20without%20cracking%20the%20molded%20plastic.&row_id=192891121815&table_id=125276734&linked_from=&referred_by=&a_b_version=) It took 5 seconds with a 2 kW EASYHEAT to reach temperature, which melted the plastic for a solid bond without cracking the molded plastic. [Heating four brass inserts for a plastic motor housing](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-four-brass-inserts-for-a-plastic-motor-housing&appnote_title=Heating%20four%20brass%20inserts%20for%20a%20plastic%20motor%20housing&meta_desc=Using%20induction%20heating,%20the%20parts%20came%20to%20the%20required%20temperature%20in%20just%2015%20seconds%20in%20a%20highly%20repeatable%20heating%20method%20and%20a%20coil%20plate%20could%20offer%20protection%20against%20operator%20movement/errors&row_id=192891121816&table_id=125276734&linked_from=&referred_by=&a_b_version=) Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors [Heat Staking Steel Parts](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heat-staking-steel-parts&appnote_title=Heat%20Staking%20Steel%20Parts&meta_desc=To%20heat%20steel%20inserts%20to%20be%20placed%20into%20a%20plastic%20frame.%20The%20end%20product%20is%20an%20automotive%20part. &row_id=192891121835&table_id=125276734&linked_from=&referred_by=&a_b_version=) To heat steel inserts to be placed into a plastic frame. The end product is an automotive part.  [Heating stainless steel inserts](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-stainless-steel-inserts-1&appnote_title=Heating%20stainless%20steel%20inserts&meta_desc=Induction%20offers%20dramatically%20faster%20heating%20when%20compared%20to%20ultrasonics;%20faster%20heating%20means%20there%20is%20the%20potential%20to%20dramatically%20increase%20production%20rates%20with%20a%20highly%20repeatable%20and%20easy-to%20integrate%20processes.&row_id=192891121817&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes. [Heating brass inserts](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-brass-inserts&appnote_title=Heating%20brass%20inserts&meta_desc=Innovation:%20Ambrell's%20Applications%20Lab%20was%20able%20to%20solve%20a%20problem%20that%20a%20competitor%20couldn't%20solve,%20which%20is%20a%20key%20benefit%20when%20purchasing%20induction%20solutions%20from%20Ambrell&row_id=192891121818&table_id=125276734&linked_from=&referred_by=&a_b_version=) Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell [Bonding plastic handles onto metal brooms](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=bonding-plastic-handles-onto-metal-brooms&appnote_title=Bonding%20plastic%20handles%20onto%20metal%20brooms&meta_desc=With%20a%20more%20reliable%20induction%20heating%20system,%20they%20will%20not%20have%20to%20worry%20about%20lost%20production%20due%20to%20power%20supply%20issues%20that%20come%20with%20an%20unreliable%20system&row_id=192891121819&table_id=125276734&linked_from=&referred_by=&a_b_version=) With a more reliable induction heating system, they will not have to worry about lost production due to power supply issues that come with an unreliable system [Metal-to-plastic insertion of threaded magnetic steel inserts](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=metal-to-plastic-insertion-of-threaded-magnetic-steel-inserts&appnote_title=Metal-to-plastic%20insertion%20of%20threaded%20magnetic%20steel%20inserts&meta_desc=Outdated%20equipment%20and%20poor%20responsiveness%20drove%20this%20customer%20to%20a%20new%20vendor%20who%20could%20help%20them%20with%20new%20or%20improved%20processes%20for%20new%20or%20enhanced%20solutions&row_id=192891121820&table_id=125276734&linked_from=&referred_by=&a_b_version=) Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions [Bonding an Arthroscopic Device](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=bonding-an-arthroscopic-device&appnote_title=Bonding%20an%20Arthroscopic%20Device&meta_desc=Induction%20is%20used%20to%20bond%20the%20device%20sheath%20to%20collet.%20Innovative%20coil%20design%20lifts%20production%20rate.&row_id=192891121821&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction is used to bond the device sheath to collet. Innovative coil design lifts production rate. [Heat a steel shaft for insertion](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heat-a-steel-shaft-for-insertion&appnote_title=Heat%20a%20steel%20shaft%20for%20insertion&meta_desc=Induction%20heating%20provides%20hands-free%20heating%20that%20involves%20no%20operator%20skill%20for%20manufacturing,%20even%20distribution%20of%20heating%20and%20localized%20application%20of%20energy%20limits%20temperature%20drift&row_id=192891121822&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating and localized application of energy limits temperature drift [Inserting brass bushing into plastic wire connector](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=inserting-brass-bushing-into-plastic-wire-connector&appnote_title=Inserting%20brass%20bushing%20into%20plastic%20wire%20connector&meta_desc=A%20three%20turn%20helical%20coil%20is%20used%20to%20heat%20the%20brass%20bushing.%20The%20brass%20bushing%20is%20heated%20for%202%20seconds%20and%20then%20placed%20on%20the%20wire%20connector%20&%20pressed%20into%20position.&row_id=192891121823&table_id=125276734&linked_from=&referred_by=&a_b_version=) A three turn helical coil is used to heat the brass bushing. The brass bushing is heated for 2 seconds and then placed on the wire connector & pressed into position. [Heating steel for insertion into polypropylene](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-steel-for-insertion-into-polypropylene&appnote_title=Heating%20steel%20for%20insertion%20into%20polypropylene&meta_desc=Induction%20heating%20provides%20'greener'%20manufacturing%20of%20pallets%20using%20reusable,%20recyclable%20materials,%20hands-free%20heating%20that%20involves%20minimal%20operator%20skill%20for%20manufacturing%20and%20even%20distribution%20of%20heating&row_id=192891121824&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction heating provides 'greener' manufacturing of pallets using reusable, recyclable materials, hands-free heating that involves minimal operator skill for manufacturing and even distribution of heating [Inserting threaded brass parts into plastic thermostat housing](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=inserting-threaded-brass-parts-into-plastic-thermostat-housing&appnote_title=Inserting%20threaded%20brass%20parts%20into%20plastic%20thermostat%20housing&meta_desc=This%20application%20has%20three%20different%20coils%20for%20varying%20hole%20patterns.%20A%20three%20turn%20oblong%20coil%20is%20used%20to%20heat%202%20brass%20inserts%20in%20close%20proximity.&row_id=192891121825&table_id=125276734&linked_from=&referred_by=&a_b_version=) This application has three different coils for varying hole patterns. A three turn oblong coil is used to heat 2 brass inserts in close proximity. [Inserting a piston stop & o-ring (oil pump)](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=inserting-a-piston-stop-o-ring-oil-pump&appnote_title=Inserting%20a%20piston%20stop%20&%20o-ring%20\(oil%20pump\)&meta_desc=Induction%20heating%20provides%20increased%20production%20speed,%20simpler%20tooling%20for%20customer,%20hands-free%20heating%20that%20involves%20no%20operator%20skill%20for%20manufacturing&row_id=192891121826&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing [Bonding electric motor shaft to nylon face fan](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=bonding-electric-motor-shaft-to-nylon-face-fan&appnote_title=Bonding%20electric%20motor%20shaft%20to%20nylon%20face%20fan&meta_desc=Induction%20heating%20provides%20hands-free%20heating%20that%20involves%20no%20operator%20skill%20for%20manufacturing,%20only%20the%20metal%20shaft%20is%20heated%20so%20the%20motor%20is%20not%20affected,%20increased%20production%20due%20to%20rapid%20heating,%20decreased%20failure%20rate,%20originally%20used%20glue%20which%20ran%20into%20motor%20and%20caused%20failure%20and%20stronger%20bond&row_id=192891121827&table_id=125276734&linked_from=&referred_by=&a_b_version=) Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond [Heating Four Inserts Simultaneously](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=heating-four-inserts-simultaneously&appnote_title=Heating%20Four%20Inserts%20Simultaneously&meta_desc=The%20brass%20inserts%20are%20to%20be%20heated%20prior%20to%20insertion%20into%20a%20plastic%20automotive%20sub%20assembly&row_id=192891121828&table_id=125276734&linked_from=&referred_by=&a_b_version=) The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly [Brass Inserts](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=brass-inserts&appnote_title=Brass%20Inserts&meta_desc=Heating%20is%20to%20be%20accomplished%20within%205%20seconds,%20and%20can%20be%20done%20in%20a%20helical%20coil%20since%20pick%20and%20place%20manufacturing%20is%20employed.&row_id=192891121829&table_id=125276734&linked_from=&referred_by=&a_b_version=) Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed. [Plastic Lawn Chairs](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=plastic-lawn-chairs&appnote_title=Plastic%20Lawn%20Chairs&meta_desc=To%20heat%20internally%20threaded%20steel%20inserts%20to%20a%20temperature%20above%20650%20°F%20for%20insertion%20into%20plastic%20lawn%20chair%20assemblies.&row_id=192891121830&table_id=125276734&linked_from=&referred_by=&a_b_version=) To heat internally threaded steel inserts to a temperature above 650 °F for insertion into plastic lawn chair assemblies. [Brassiere Underwire](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=brassiere-underwire&appnote_title=Brassiere%20Underwire&meta_desc=To%20heat%20the%20ends%20of%200.072-inch%20spring%20wire,%20spaced%201/2%20inch%20apart,%20uniformly%20for%20the%20application%20of%20nylon%20powder%20on%20a%201inch%20length%20of%20the%20end.&row_id=192891121831&table_id=125276734&linked_from=&referred_by=&a_b_version=) To heat the ends of 0.072-inch spring wire, spaced 1/2 inch apart, uniformly for the application of nylon powder on a 1inch length of the end. [Inserting Steel Studs into a Plastic Tail Light](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=inserting-steel-studs-into-a-plastic-tail-light&appnote_title=Inserting%20Steel%20Studs%20into%20a%20Plastic%20Tail%20Light&meta_desc=To%20heat%20threaded%20steel%20studs%20for%20insertion%20into%20a%20plastic%20tail-light%20assembly%20at%20450%20°F.&row_id=192891121832&table_id=125276734&linked_from=&referred_by=&a_b_version=) To heat threaded steel studs for insertion into a plastic tail-light assembly at 450 °F. [Metal-to-Plastic Insertion with a Steel Insert](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=metal-to-plastic-insertion-with-a-steel-insert&appnote_title=Metal-to-Plastic%20Insertion%20with%20a%20Steel%20Insert&meta_desc=The%20power%20was%20turned%20on%20for%20five%20seconds%20and%20the%20part%20was%20monitored%20during%20heating%20and%20for%2015%20seconds%20after.&row_id=192891121833&table_id=125276734&linked_from=&referred_by=&a_b_version=) The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after. [Metal-to-Plastic Insertion with a Brass Shaft](/induction-heating-applications/appnote-request?lead_origin=heat%20staking&appnote_filename=metal-to-plastic-insertion-with-a-brass-shaft&appnote_title=Metal-to-Plastic%20Insertion%20with%20a%20Brass%20Shaft&meta_desc=Multiple%20torches%20were%20required%20for%20this%20application%20previously,%20so%20the%20compact%20EASYHEAT%20minimized%20the%20required%20footprint%20for%20heating.%20With%20induction%20you%20can%20expect%20the%20same%20result%20every%20time,%20while%20variability%20is%20often%20observed%20with%20a%20torch&row_id=192891121834&table_id=125276734&linked_from=&referred_by=&a_b_version=) Multiple torches were required for this application previously, so the compact EASYHEAT minimized the required footprint for heating. With induction you can expect the same result every time, while variability is often observed with a torch ## heat staking Resources ##### Select an option below: - Design Guidelines - Application Note Volume Offers - Other Resources Thermoplastics will flow at elevated temperatures and the solidified polymer can be re-heated to re-flow around the insert. Thermosetting polymers, once the shape has been cast, will no longer melt or flow on reheating. Table 1 shows some typical temperatures, time and power required for different materials, as established in the Ambrell Applications Lab. The diameter of the insert hole must be the correct size to allow the plastic to flow around the insert. If the hole is too small,extra plastic will be displaced. This displaced plastic is commonly called ‘flash.’ Excessive heat and pressure may also cause flash. If the hole is too large, not enough plastic will flow into the fins and knurls to achieve the desired holding strength. ## 10 Induction Heating Application Notes [](https://www.ambrell.com/appnote-request?lead_origin=heating&appnote_filename=Induction%20Heating%20Application%20Notes%20Volume%201&appnote_title=Induction%20Heating%20Application%20Notes%20Volume%201&linked_from=appnote%20cards)We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your heating processes. ## 10 Automotive Application Notes [](https://www.ambrell.com/appnote-request?lead_origin=heating&appnote_filename=Automotive%20Manufacturing%20AppNotes%20Volume%201&appnote_title=Automotive%20Manufacturing%20AppNotes%20Volume%201&linked_from=appnote%20cards)We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your precision automotive manufacturing processes. [ ### Blog Posts ](https://www.ambrell.com/blog/topic/heat-staking) #### Headline Add your content here. ### Videos ](https://www.ambrell.com/learn/application-videos) #### Headline ### Brochure ](https://www.ambrell.com/induction-heating-brochures/metal-plastic-insertion?lead_origin=heat-staking&appnote_filename=411-0172-10&appnote_title=Heat%20Staking%20Design%20Guide:%20Inserting%20Metal%20into%20Plastic%20with%20Induction) #### Headline ### Collection ](https://www.ambrell.com/induction-heating-applications/heat-staking-collection) #### Headline ## Our Systems for heat staking with Induction ### EASYHEAT Models ](https://www.ambrell.com/products#easyheat) #### Headline ### EKOHEAT Models ](https://www.ambrell.com/products#ekoheat) #### Headline ### Workhead Models ](https://www.ambrell.com/products/workheads) #### Headline ### Product Spectrum ](https://www.ambrell.com/products#spectrum) #### Headline Four Ways To Contact Ambrell for Support [](https://www.ambrell.com/products/demo-request) [Request a Demo](https://www.ambrell.com/products/demo-request) [](https://www.ambrell.com/contact-us) [Give Us a Call](https://www.ambrell.com/contact-us) [](mailto:sales@ambrell.com) [Send an Email](mailto:sales@ambrell.com) [](https://www.ambrell.com/services/applications-lab) [Free Lab Services](https://www.ambrell.com/services/applications-lab) ### AMBRELL CORPORATION 1655 Lyell Avenue Rochester, NY 14606 United States  [](//www.ambrell.com/directions) [Directions](//www.ambrell.com/directions) [T: +1 585 889 9000](tel:15858899000) F: +1 585 889 4030 [Contact Sales](mailto:sales@ambrell.com) [Contact Orders](mailto:ambrellorders@ambrell.com) [Contact Service](mailto:service@ambrell.com) ### AMBRELL B.V. 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