Mirror welding is a manufacturing process for thermal joining of plastic parts. Flat surfaces are melted by contact with a heating plate and then pressed together by pressure. During this process the melted edges solidify and a weld seam is formed.
Your specialist for plastic tanks and containers
As an experienced supplier for the automotive industry we have specialized in the production of plastic containers and tanks. For plastic tanks, which cannot be produced with Blow Moulds due to their geometry, half-shells have to be injection moulded and then welded into tanks. The only alternative is rotational moulding, which, however, reaches its limits with higher quantities.
Development and adaptation of plastic containers
Depending on requirements, we support our customers in development and design or develop a container independently according to customer specifications. Frequently, already existing containers made of sheet metal are to be transferred to more cost-effective plastic tanks. Here, some points have to be considered which must be taken into account in the design. In addition to a production-optimised component geometry, stiffening ribs, wall thicknesses, fixing straps, threaded bushings, interfaces and baffle plates etc. must be accommodated. At the same time, pressures, temperatures, media resistance and weathering must be taken into account in the product life cycle. Thanks to our many years of experience in tank construction, we can provide our customers with comprehensive advice.
Production of complex plastic tanks
Since hollow bodies cannot be injection molded, complex plastic tanks must first be disassembled into individual parts that can be removed from the mold. Often it is sufficient to divide the tank into two halves at a convenient location. These can be injection moulded without any problems. The half shells are then joined together by mirror welding or hot plate welding to form a hollow plastic tank. With this process, complex tank geometries with constant wall thicknesses can be produced. In addition, inserts (e.g. threaded bushes) can be easily and safely overmoulded.
In order to be able to guarantee the tightness of the weld seam, all plastic tanks are finally tested 100% with compressed air under water and the test result is then documented.
Application areas of the plastic tanks
- Wash water tanks
- Reserve tanks
- and many more
- Compensation tanks
- Fuel tanks
- Adblue Tanks
- Water Tanks
Advantages of injection moulding and subsequent mirror welding
- Production of complex plastic bodies
- Connection points for hoses etc. can be easily implemented by injection moulding
- Creating undercuts
- suitable for small and large series
- Metal insert for fastening further components
- minimal reworking
- Plastic parts with exact wall thicknesses can be realized
- simple procedure and short cycle times
- automated manufacturing process
More than just mirror welding
- Component assembly
- Batch traceability and serial number assignment possible
- 100 % leak test under water
- Documented test results
- machining post-processing
- Surface refinement
Use our all-round service
- Personal customer advice and support
- New development, further development, cost optimization
- Creation of concept drawings, production drawings and material lists (BOM)
- Fast prototyping
- Creation of initial sample inspection reports (ISR)
- Demand-oriented production
- International serial supply
- Computer-aided process documentation
- Batch Traceability
- Continuous quality monitoring
Any more questions?
We are happy to advise you and provide you with a non-binding offer.