Model BTP — Benchtop Heat Staking Press

The Model BTP is our production-grade benchtop heat staking and brass inserting press. Pneumatic ram, impulse-heated tooling, 0.1 mm encoder accuracy on the head position, and support for up to eight stakes or inserts in a single cycle. It is the right machine when you need real production throughput without committing to a full automation cell, and it scales from prototype runs to multi-thousand-piece-per-shift production with the same tooling philosophy.

Patent-pending Weld by Energy control means one setting per joint — the press delivers a metered amount of energy and stops, rather than running a heater for a fixed time and hoping the resin behaves. Cycle behaviour is repeatable across long runs, drift-prone resins, and operator changes. The press records every cycle, so process records are auditable and survive a customer Cpk audit without operator handwaving or "the timer was set to 30 seconds" arguments.

What the BTP Does

Impulse heat staking for forming plastic bosses into permanent head-style fasteners. Brass, stainless, and aluminium insert installation for permanent threaded connections in plastic. Multi-up cycles for up to eight stakes or inserts simultaneously. Programmable recipes for multiple part numbers stored on the controller. Energy-metered cycle control with no time-based dialling-in. Encoder-based head positioning for verifying boss height before the cycle starts — the press knows whether the boss is actually there.

Specifications at a Glance

Pneumatic ram (compressed air supply required), impulse-controlled tip heating, compressed air tip cooling for clean retract, 0.1 mm encoder accuracy on head position, up to 8 tips per cycle with custom multi-up tooling, programmable recipes per part number, energy-per-joint cycle control, auditable cycle log for process documentation. Tooling, fixturing, and nests are engineered around the specific part as part of every order — we do not ship a generic tip and hope it fits.

Typical Applications

PCB-into-housing assembly for electronics; automotive interior trim and lighting bezel staking; brass insert installation in cosmetic plastic parts for consumer products; multi-up consumer product assembly; medical device housings with cleanroom-compatible cycle behaviour; any heat staking job that needs cosmetic-grade results at production speed. The same machine handles all of the above — tooling changes between recipes, the press stays the same.

How to Quote a BTP

Send a part drawing, the resin grade, the production volume target, and a brief description of the joint you need formed (stake count, boss geometry, cosmetic requirements). We return a quote with the recommended tooling, the cycle time estimate, the lead time, and a fixed price within 24 hours. Request a quote or call (614) 549-0627.

Related Pages

For the underlying staking technology see Impulse Heat Staking and Brass Insert Installation. For larger automation systems see Custom Automation. For design rules and troubleshooting, see the Design Guide and Common Failures resources, or the blog.