Production requirement

How the system addresses it

Contoured seam control

Heated tooling is designed around the lamp geometry and thermal load.

Optical-surface protection

Fixture contacts and handling avoid pressure or abrasion on critical surfaces.

Functional validation

Leak, dimensional and appearance checks are tied to the machine acceptance plan.

Maintainable tooling

Cleaning access, replaceable contact surfaces and service points support stable production.

Application

Typical joining requirement

Headlamp housing

Continuous seam between compatible thermoplastic housing components.

Taillamp

Housing and cover assemblies requiring appearance and sealing control.

Fog / signal lamp

Compact contoured thermal joints and variant tooling.

Light-guide housing

Sensitive internal components requiring controlled fixture support.

Lamp subassembly

Custom thermal joining before final leak or functional testing.

Configuration

Architecture

Best fit

Pneumatic platform

Robust force/pressure-based motion

Suitable when the validated process does not require servo profiles.

Servo platform

Programmable position and speed

For tighter displacement control and recipe flexibility.

Quick-change servo

Standardized tool interface

For multiple lamp variants on a shared platform.

Integrated test cell

Weld plus leak/vision test

For one-piece flow and controlled release.

Parameter

Reference value

Engineering note

Reference model

DZ-350 / DZ-800S / DZ-1000SF

Pneumatic / servo / quick-change servo family

Reference max. weld area

350×200 / 800×450 / 1000×600 mm

Confirm against actual part envelope

Reference machine size

1400×1500×2100 to 2200×2400×2800 mm

W×L×H; project layout may differ

Power supply

380 VAC reference

Destination standard to be confirmed

Heated tool

Contoured, multi-zone

Designed to lamp seam

Motion

Pneumatic or servo

Selected by control plan

Tool cleaning

Manual or automatic option

Method validated for tooling/coating

Fixture

Optical-surface protective

Part-specific support

Leak testing

Optional integration

Test method and limits by customer

Cycle time

Project-specific

Includes heating, changeover, joining and cooling

Parameter

Engineering purpose

Tool temperature by zone

Controls heat distribution; use independent PID zones and deviation alarms where required.

Matching / bead-up setting

Establishes contact and compensates for molded-part variation.

Heating time or melt displacement

Develops the melt layer without excessive degradation.

Open / changeover time

Limits cooling and oxidation of the molten surfaces before joining.

Joining force, pressure and speed

Controls melt flow, flash and interface formation.

Weld collapse / final position

Supports dimensional consistency and can be monitored when specified.

Hold and cooling time

Prevents joint movement before sufficient strength develops.

Tool cleaning condition

Supports consistent heat transfer and protects sensitive cosmetic surfaces.

Control element

Available project function

Temperature control

Zone setpoints, actual values, deviation alarms and warm-up release conditions.

Motion and position

Servo or sensor feedback for matching, changeover, joining and final position where included.

Force / pressure monitoring

Project-specific transducer or regulated pneumatic/hydraulic control.

Recipe management

Part-specific temperatures, timings, motion values and inspection limits.

Functional testing

Optional leak, pressure-decay, flow, burst or dimensional checks after welding.

Data exchange

Cycle results and selected parameters can be exported when the interface is included in the scope.

Leak-test interface

Cycle ID and weld result can be associated with the downstream test result when included.

Tool cleanliness

Cleaning confirmation or service counter supports stable heat transfer.

Final position

Servo/displacement limits can detect abnormal collapse or incomplete seating.

Optical protection

Part-presence and fixture checks prevent clamping on sensitive features.

Material or design factor

Application guidance

PP and PE families

Common candidates for tanks, reservoirs, pallets and fluid-handling products.

ABS and PC/ABS

Suitable for selected housings and appliance components after grade-level testing.

PA and filled engineering thermoplastics

Moisture and reinforcement can change the thermal process window.

PMMA, PC and optical applications

Protect cosmetic surfaces and validate thermal response and joint design.

Dissimilar resins

Possible only for compatible combinations; verify exact grades and melting behavior.

Option

Project scope

Platform

Pneumatic, servo or quick-change servo architecture.

Heating zones

Independent PID zones and deviation alarms around the contoured seam.

Cleaning

Manual access, wiper, brush or application-specific automatic cleaning.

Testing

Pressure decay, flow or customer-defined leak test after welding.

Inspection

Vision for part presence, flash, connector or marking checks.

Clean handling

Protective covers, ionized air or controlled cleaning according to lamp requirements.

Poka-yoke

Part presence, orientation, variant, insert, fixture and tool verification.

Traceability

Barcode/QR/RFID, cycle-result storage and customer-defined data fields as an option.

Inspection

Vision, displacement, force, leak, pressure, flow or dimensional checks according to the CTQ plan.

Line communication

Signals or industrial network interface; MES connection only when explicitly included.

Safety

Interlocked guarding, safety doors/light curtains, emergency stops and safe reset concept to destination requirements.

Service package

Training, recommended spares, preventive-maintenance plan, remote support and optional on-site support.

Acceptance activity

Typical evidence

Documented scope review

Approved specification, layout, utilities, interfaces, cycle definition and exclusions.

Tool and datum verification

Part location, clamp support, tool identity and changeover checks.

Process-window trials

Representative production parts across agreed material and dimensional variation.

Quality checks

Agreed visual, dimensional, strength, leak, burst or functional test with defined limits.

Repeatability run

Quantity, run duration, operator conditions and acceptance method agreed before FAT.

Safety validation

Guarding, interlocks, emergency stops, reset behavior and maintenance access.

Data and alarm test

Recipes, access levels, pass/fail windows, alarms, identifiers and interface signals.

Training and handover

Operation, changeover, maintenance, backup/restore and agreed documentation.

Stage

Main input or activity

Output / decision

1. Application review

Parts, materials, joint, CTQs, takt and plant standards

Feasibility risks and missing inputs

2. Concept and quotation

Process choice, layout, tooling, controls, interfaces and exclusions

Approved technical and commercial scope

3. Trials and samples

Production-equivalent parts and agreed test method

Process window and sample evidence

4. Detailed engineering

3D design, risk review, I/O, safety and documentation plan

Customer design approval

5. Build and debug

Machine, tooling, programs and internal run-off

Ready-for-FAT review

6. FAT

Agreed parts, run quantity, quality checks, takt and documents

Punch list and shipment release

7. Installation and SAT

Utilities, setup, training and site acceptance run

Production handover by agreed scope

Please provide

Why it is needed

Lamp and mating-part 3D data

Used to check envelope, datums, access, tooling and machine layout.

Seam cross-section and flash allowance

Required to complete the technical concept and remove quotation assumptions.

Exact resin grades and colors

Required for process feasibility and a grade-level trial plan.

Optical/Class-A protection zones

Required to complete the technical concept and remove quotation assumptions.

Leak-test method and limits

Defines measurable trial, FAT and SAT acceptance criteria.

Takt, variants and cleaning requirements

Used to size stations, automation, changeover and capacity.

Question

Answer

Can hot plate welding make a leak-tight lamp assembly?

It can produce a continuous sealed joint when material, seam design, molding and process are suitable. The required leak limit must be confirmed by representative-part testing.

Can the machine weld a transparent lens to a housing?

Only after reviewing the exact resin grades, coating, thermal behavior and appearance requirement. The process is approved at material-grade level, not by generic names alone.

Why is tool cleaning important?

Plastic residue or coating on the heated tool can change heat transfer and mark the seam. Cleaning method and frequency are part of the validated maintenance plan.

Can leak testing be integrated?

Yes. The test method, stabilization time, limit, fixture and data association must be defined in the project scope.

What information is required for an application review?

Please send part 3D data and drawings, exact resin grades, joint or stake details, production-equivalent samples if available, CTQ and test requirements, takt, annual volume, variant mix, utilities and plant standards.

Can Dizo Sonics test our real parts before quotation?

Yes. An application review and representative-part trials are recommended when feasibility, tooling concept or cycle assumptions need evidence. Trial scope, sample quantity and test method are agreed before testing.

How is the final cycle time confirmed?

The committed cycle is based on trials and a complete sequence study including loading, clamping, joining, cooling, inspection, data handling and unloading. Published reference cycles are not universal guarantees.

Which plastic materials can be processed?

Suitability is approved at exact-grade level. Resin chemistry, fillers, moisture, additives, color, recycled content, molded-part variation and joint design can all change the process window.

What documents are supplied with the machine?

The project handover package can include the approved specification and layout, electrical and pneumatic documentation, manuals, maintenance plan, spare-parts list, parameter backup, inspection records and FAT documents according to the contract.

Do you support FAT, installation and SAT?

Yes. FAT and SAT activities are defined in the project plan. Installation, training and on-site support depend on destination, responsibility split and the commercial scope.