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Assembly Considerations
In ultrasonic staking, the high-frequency vibrations from a specially contoured horn melts the top of a thermoplastic stud which protrudes through a hole in the mating part of an assembly (mating material can be a dissimilar plastic or metal).
Staking designs can vary, depending on the diameter needed to hold the two components together. When the top of the stud melts, it forms a head that locks the two components together. The base of the stud should be rounded to reduce any stress concentration. The through hole on the mating part should be a close fit to prevent melt from flowing into the gap between the stud and mating part.
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