Weld
Beyond
Limits
Emabond harnesses high-frequency RF energy and specially formulated electromagnetic susceptor materials to deliver controlled, non-contact heat — creating hermetic seals across even the most complex thermoplastic geometries.
How Emabond Welding Works
A proven four-stage process from part analysis to production-ready welds — all engineered in-house.
Joint Design
Our engineers design optimal joint geometry for your specific part and application requirements.
Susceptor Formulation
Custom electromagnetic susceptor material formulated for your resin and weld requirements.
Fixture & Machine Build
In-house design and fabrication of welding fixtures and RF welding equipment.
Test & Verify
Full RF coil, power, and fixture testing before customer sign-off on part specifications.
Everything Built
In-House
Emabond engineers design, build, and test customer welding fixtures, manufacture machines, and validate applications — all before the customer gives verification. This means tighter control, faster iteration, and guaranteed results.
Request a ConsultationJoin the World's
Most Recognized Brands
Our customers are market leaders across water filtration, consumer products, office furniture, medical, and transportation. If you have a high-demand application requiring hermetic seals, strength, or complex geometries — reach out today.
Request a Free Consultation →Where Emabond Delivers Results
From automotive to medical — if it is a thermoplastic that needs reliable joining, Emabond has a proven solution.
Wastewater Holding Tank and Pump
- Hermetic Seal
- High cost of failure mitigation
- Replaced expensive gaskets and screws
Acrylonitrile butadiene styrene (ABS)
Dual Weld Line — 52 inch perimeter, 44 inch internal weld line
Radon Fan Housings
- Vapor Proof
- Hermetic seal
- Un-welding capabilities to harvest internal components
- Replaced expensive gasket and screws
- High cost of failure mitigation
Polycarbonate (PC)
31 and 40 inches of weld line across 2 sizes of housings
Outdoor Water Meter Endpoint
- Delicate metal transmitter contained within housing
- Requires 20 year service life in severe environments
- Leakproof, flash free welds required
PC/ABS to TPO — Utilizes Emabond "Formed Ring"
Dissimilar material weld joint, 4 in. diameter
Hood Ornament: Trail Sights
- High Strength Requirement
- Clean, aesthetic weld lines
- Hermetic seal required
- 2 shot injection molded Emabond material
30% Glass filled polypropylene (PP)
Outdoor Loudspeaker
- Two weld lines
- Pressure-tight
- Weather resistant from -40 to 150°F
- Structural enclosure
- Pre-assembled electronic components
Glass-filled polypropylene (PP)
74" of total weld across two separate weld lines
Automotive Speaker Cross Vehicle Beam
- Clean, aesthetic weld line
- Complex 3D geometry
- Eight interior rings creating a waterproof seal
- Internal components pre-assembled
Polypropylene (PP)
11 separate welds with over 13 feet of total weld line
Ergonomic Office Chair
- Complex 3D geometry
- Flexible to rigid — dissimilar material
- Allows creation of a truly "flexible seating design"
- Two separate clean distortion free weld lines
Flexible hytrel elastomer to glass reinforced polyester
Upper and lower seat back totaling 70" of three dimensional weld line
Innovative Seating Stool
- Domes are airtight
- Inflated with zero pressure decay over 100,000 test cycles
- Structural and durable
- Three separate weld lines
- Dissimilar materials
Talc-filled polypropylene (PP) to thermoplastic vulcanizates (TPV)
Three separate welds with over 80" of total weld line
Fiber Optic Cable Housing
- Hermetic, long-term outdoor rated
- Elimination of gaskets & fasteners
- Flash-free and distortion-free weld line
- Non-contact, stress free
- Fiber pre-assembled prior to welding
- Reversible process enables costly component recovery
Polypropylene (PP), Glass-filled PP, Polycarbonate (PC)
Various configurations ranging from 18" – 24" of total weld line
Bumper License Lamp Bezel
- High pull force requirement (+500N)
- Clean, aesthetic weld lines
- Hermetic seal required
- Two bezels simultaneously welded
- Stamped gasket to match unique geometry
Thermoplastic polyolefin (TPO) to polypropylene (PP)
2¼" x 2¾" each weld
RV and Camping Toilets
- Clean distortion free weld on as thin as 1.5 mm wall thickness
- Replaced hotplate and adhesives due to high cost of failure
- Structural leak-proof welds
- Long 3D and/or multiple weld lines
Polypropylene (PP)
Multiple applications ranging from 18" – 125" of total weld
Portable Camping Toilets
- Replace blow-molded components to allow internal features
- Allowed thinner-walled, lighter parts
- Ability to join multi-material and multi-colored parts
- Leak-proof
- Multiple styles utilizing quick change tooling
Polypropylene (PP)
Several configurations with multiple weld lines totaling up to 12 feet
Pressure Assist Flush Tanks
- Burst pressure = +300 psi
- Long irregular shaped weld line
- Highly glass-filled material
- Highly reliable
- Compensates for lack of close molding tolerances
Long glass polypropylene (PP)
Main perimeter: 37", Valve: 1¼" diameter, Discharge: 3½" diameter
Weld What
Others Can't
Emabond's susceptor material technology enables welding of virtually all thermoplastics — including dissimilar material pairs that are otherwise incompatible.
- ABS / ABS Alloys
- TPE / TPO / TPU / TPV
- Nylon (PA6/PA66)
- PC — Polycarbonate
- PC / ABS Blend
- HDPE / LDPE
- PP — Polypropylene
- PVC — Flexible / Rigid
- Noryl GTX / PPO / PPX
- PBT / PC-Xenoy
- Highly Filled Plastics (glass/talc)
EMABOND WELDING — Material Compatibility Guide
| Material Family | ABS | Elastomer | Hybrid | Noryl GTX | Nylon | EVA | PBT | PBT/PC | PC | PCL | ABS | HDPE/LDPE | Polyester | PMMA | PP | PVC |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| ABS | ||||||||||||||||
| TPE/TPO/TPU | ||||||||||||||||
| Hytrel Polyester | ||||||||||||||||
| Noryl GTX/PPO | ||||||||||||||||
| Nylon (PA6) | ||||||||||||||||
| EVA Foam | ||||||||||||||||
| PBT | ||||||||||||||||
| PBT/PC-Xenoy | ||||||||||||||||
| PC-Polycarbonate | ||||||||||||||||
| PC/ABS | ||||||||||||||||
| PCL-Polycaprolactone | ||||||||||||||||
| HDPE/LDPE | ||||||||||||||||
| Polyester | ||||||||||||||||
| PMMA-Acrylic | ||||||||||||||||
| PP-Polypropylene | ||||||||||||||||
| PVC flex/rigid |
Case Studies
& Articles
Delivering Leak-Proof, Lightweight Coolers with Advanced Plastic Welding
A leading insulated cooler manufacturer needed to move away from adhesives to achieve superior hermetic seals while reducing assembly complexity.
Outdoor Water Meter Endpoints
Lasting hermetic seals in dissimilar materials, even in harsh outdoor environments.
Vapor-Proof Radon Fan Housings
Delivering vapor-proof seals and cutting production costs with Emabond technology.
Redefining Plastic Joining: Welding PC to PP/TPO
How Emabond joins previously incompatible polymers that traditional methods cannot weld.
The No-Cure-Time Advantage Over Adhesives
Time is money. Emabond eliminates cure times, accelerating production throughput immediately.
Common
Questions
Get answers to the most frequently asked technical questions about Emabond's plastic welding process.
View All FAQs