Short Welding Times And High Strength

Plastic Welding Short Welding Times And High Strength

2026-05-27 From BASF | Translated by AI 2 min Reading Time

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BASF has patented a hot gas welding process for plastics with which thermoplastic components—especially those made of Ultramid Advanced (polyphthalamide PPA)—can be welded faster, more energy-efficiently and with less stress on the material than with conventional hot gas welding processes.

Tests on PPA test specimens have shown that the patented hot welding process can produce resilient welded joints after very short heating times of around ten seconds.(Image: BASF) — Tests on PPA test specimens have shown that the patented hot welding process can produce resilient welded joints after very short heating times of around ten seconds.
(Image: BASF)

At the heart of the patented solution is a special tool design: The hot process gas is no longer blown selectively from individual nozzles onto the welding bars, but is instead guided along the welding bars via channel-like structures. This distributes the gas evenly and minimizes heat loss. The welding bars are plasticized more homogeneously without the need for high gas temperatures or very small nozzle distances.

Produce Resilient Welded Joints in Just Ten Seconds

"Tests on PPA test specimens have shown that the patented process can produce resilient welded joints after very short heating times of around ten seconds," says Stefan Mochev, Team Leader Materials & Parts Testing. "In comparison, with conventional hot gas welding technologies, it is often not possible to produce a joint at all with these short times. At the same time, high weld seam strengths are achieved, which makes the technology particularly attractive for functionally integrated components with high mechanical requirements."

Another advantage is the greater melt layer thickness that can be achieved within a short time. This offers additional scope to compensate for component distortion—an important aspect for large-format or complex components.

More Efficiency And Process Reliability

The patented hot gas welding process enables lower process temperatures and therefore reduces the consumption of energy and inert gas. In addition, the distance between the gas nozzles and welding bars can be increased, virtually eliminating the risk of individual nozzles becoming blocked by molten material. This increases process reliability and reduces maintenance costs.

Contribution to Sustainable Mobility Solutions

Due to their high thermal, chemical and hydrolytic resistance, polyphthalamides are key materials for applications in electromobility and fuel cell systems. With its patented hot gas welding process, BASF is expanding the processing possibilities of this material class and helping customers to join components more efficiently and further increase functional integration.

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