Manufacturing

The Pinweld technology is able to accurately join thermoplastic components by fusing material in a continuous process along a discreet weld path. This novel ability is easily integrated with existing production equipment or advanced robotic systems to provide manufacturers with new opportunities. With our recent advancements, the technology is ideally positioned to become the first continuous linear welding technique for a range of high-value polymer types including recycled and bio-derived variants.

The flexibility of the Pinweld technology is increasing as we employ our Machine Learning and AI algorithms to enhance the capabilities of the technology and add to the range of polymers we test.

A further advantage of the technique is its ability to create welded joint designs not currently possible using existing techniques. This will allow designers to reduce component count in a lightweighting application, but also permit new designs such as laminar sheet welding and intermittent fusion between strengthening composite structures.

Notable about Pinweld, is that the energy used is significantly lower than all other plastic welding methods as the heat is localised in just the welding pin and together with the dynamic forces generated within the process, this promotes a stronger and more ductile weld.

With the latest industry statistics (Plastikmedia 2024) manufacturers in the plastics industry say that expenditure on energy accounts for over 20% of their costs. Consequently, seeking out ways to reduce costs and mitigate the impact of ever rising costs, places an added focus on adopting a new way of working using advanced processes like Pinweld to manufacture parts.

Mounted on an advanced robotic system, the Pinweld technology will provide accurate, automated and reliable linear welds free from deformation and using less energy than a typical laptop at around 40 Watts. While the technology will revolutionise niche industries where automated welding of polypropylene and polyethylene just isn’t available, it is also ideally suited to large volume sectors such as automotive which are highly price-sensitive and therefore need to develop more cost-effective processes to remain competitive and reduce reliance from imports.

Manufacturing

Due to the novel way the Pinweld technology works which essentially joins the component parts by replicating the original moulding conditions on a microscopic scale along a joint, it is ideally positioned to be the first linear welding technique for large plastic structures including those made from recycled and bio-derived polymers.

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Automotive

Approximately 700,000 bumpers are being replaced in the UK each year, many with only minor damage. The focussed challenge we are addressing is that currently it is virtually impossible to repair cracks in most plastics without damaging them further due to excessive heat required in existing repair processes.

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Polyethylene Pipes

The latest Innovate UK grant supported project is to investigate a new and innovative method of joining Polyethylene (PE) pipes, an area that has not seen much innovation in the past twenty-five years. The Pinweld technology will deliver leak free joints, with no heating or cooling cycles, in a highly compact solution for both new networks and repairs.

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