Assembly & Sequenced Supply

We supply complex sub-assemblies and modules line side to our customers daily, from engine covers to roof modules, dashboards to door assemblies, caravan front panels to shower trays and bulkheads to bumper systems.

A bespoke approach

Our assembly teams at our Rutland and Cannock manufacturing sites undertake a range of complex techniques from structural adhesives to ultrasonic welding. We provide full in-house training and are always evolving to meet new customer demands with efficiency and sustainability as our priorities.

Assembly of plastic components

The assembly of plastic components involves joining individual parts together to create a complete product or sub-assembly. Plastic components are commonly used in various industries, and the assembly process can vary depending on the complexity of the product and the specific requirements.

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Plastic component assembly methods:

Adhesive bonding

Adhesive bonding involves using specialised adhesives or glues to join plastic parts together. The adhesive is applied to the bonding surfaces, and the parts are then pressed together. This method is suitable for bonding plastics that cannot be easily joined using other methods, providing a clean and aesthetically pleasing finish.

Mechanical fastening

Mechanical fastening methods, such as screws, bolts, nuts, and rivets, can be used to assemble plastic components. Inserts or metal threaded fasteners may be embedded in the plastic parts to provide secure connections.

Snap-fit assembly

Snap-fit assembly involves designing plastic parts with specific features that allow them to interlock or snap together without the need for additional fasteners. Snap-fit connections are quick and easy to assemble and disassemble, making them popular in consumer products.

Heat staking

Heat staking involves using localised heat to soften specific areas of the plastic components, allowing them to be joined together by pressure or other means. This method is commonly used for joining plastic parts with bosses or protrusions.

Solvent welding:

Solvent welding involves using a chemical solvent that dissolves the plastic surfaces to be joined, fusing them together when the solvent evaporates.

Ultrasonic welding 

Ultrasonic welding utilises high-frequency vibrations to create heat, which melts the plastic at the joint interface. Once the plastic cools and solidifies, a strong bond is formed between the two components.

Here is one of our KUKA robotic ultrasonic welding machines, which is used for complex door assembly. One of the advantages of this welding robot is it can reach difficult locations and can execute complicated tool paths and welds effectively.

The choice of assembly method depends on factors such as the type of plastic, the design of the components, the required strength of the assembly, and the production volume. Each method has its advantages and limitations, and manufacturers select the most appropriate one based on the specific application and project requirements.

Get in touch

At Linecross we provide a complete ‘concept to production’ service from customised product development to assembly and sequenced supply. Find out more about how our range of processes can support your business.

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