Servo Hot Plate Plastic Welding Machine

Production requirement

How the system addresses it

Motion control

Servo profiles support repeatable position, speed and collapse management.

Thermal control

Independent zones and alarms keep the heated tool within the validated range.

Application tooling

Contoured heated plates and supported fixtures follow the actual part geometry.

Scalable automation

Manual loading, shuttles, robots, testing and line interfaces can be added by scope.

Application

Typical joining requirement

Automotive reservoir

Continuous seam and optional leak-test integration.

Plastic pallet

Large-area supported joining for upper and lower sections.

Appliance housing

Contoured seam with cosmetic and dimensional controls.

Industrial container

Large PP/PE or compatible thermoplastic assembly.

Custom plastic product

Feasibility determined from resin, joint, geometry and acceptance criteria.

Configuration

Architecture

Best fit

DZ-350

Pneumatic

Reference weld area up to 350×200 mm.

DZ-800S

Servo

Reference weld area up to 800×450 mm.

DZ-1000SF

Quick-change servo

Reference weld area up to 1000×600 mm.

Custom platform

Application-specific

For envelopes, force, tooling or automation outside the reference family.

Parameter

DZ-350

DZ-800S

DZ-1000SF

Model

DZ-350

DZ-800S

DZ-1000SF

Motion

Pneumatic

Servo

Quick-change servo

Reference max. weld area

350×200 mm

800×450 mm

1000×600 mm

Reference machine size (W×L×H)

1400×1500×2100 mm

2000×2200×2600 mm

2200×2400×2800 mm

Power supply

380 VAC reference

380 VAC reference

380 VAC reference

Temperature control

PID zones

PID zones

PID zones

Tool change

Project-specific

Project-specific

Quick-change reference

Cycle / capacity

Application-specific

Application-specific

Application-specific

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.

Warm-up release

Automatic production is enabled only after all required thermal zones are stable.

Servo position windows

Matching, melt and final-position results can be compared with recipe limits.

Recipe governance

Variant settings and editing rights reduce uncontrolled parameter changes.

Maintenance counters

Tool cleaning, lubrication and service actions can be prompted by cycles or time.

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 size

Reference family or custom envelope based on part and tooling study.

Motion package

Pneumatic or servo axes for heating-tool transfer and joining motion.

Tool interface

Dedicated, cart-assisted or quick-change connections with tool ID.

Temperature system

Independent zones, standby control, deviation logging and protected tuning.

Post-weld test

Leak, flow, vision, dimension or mechanical-test interface.

Loading concept

Manual, ergonomic shuttle, rotary table, conveyor or robot handling, selected by takt and risk assessment.

Controls

PLC/HMI brand, recipe capacity, user levels, languages and remote-support method confirmed by project.

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

Upper/lower part 3D and drawings

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

Exact resin grades and fillers

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

Seam cross-section and joint length

Required to complete the technical concept and remove quotation assumptions.

Part envelope and tool-change requirement

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

Strength/leak/dimensional acceptance limits

Defines measurable trial, FAT and SAT acceptance criteria.

Takt, loading concept and utilities

Used to size stations, automation, changeover and capacity.

Question

Answer

Which model should we choose?

Selection depends on part envelope, seam size, tool mass, force, motion control, changeover and automation—not only the nominal weld area.

What is the benefit of servo motion?

Servo axes provide programmable speed and position profiles plus result monitoring, which can improve control where collapse or CTQ dimensions matter.

Can one machine weld several products?

Yes, when the products fit the platform and a validated quick-change strategy is practical. Each variant still needs dedicated tooling and a qualified recipe.

What cycle time can you guarantee?

Cycle time is confirmed after thermal trials and a sequence study because heating, changeover, joining, cooling, loading and testing all contribute.

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.