Variable-Diameter Die Opening

Direct-Contact Heating

Rapid Setup and Processing

Variable-Diameter Die Opening

Direct-Contact Heating

Rapid Setup and Processing

Model WX Plastic Welder

Model WX Hot Crimp Welder is a unique machine for bonding, welding, or reflowing tubular-shaped plastic assemblies.

The welder consists of a variable-diameter hot-die mechanism designed to have minimal friction, allowing the closed-loop force control to be accurate and responsive, even at very low force levels. An assembly of thermoplastic parts covered by a heat-shrink tube is inserted into the opening and then the dies are closed on to the joint. The mechanism follows the tubing as it shrinks, maintaining direct thermal contact around the whole circumference. This results in repeatable welding temperature and process consistency.  All the motion is guided by precision ball-bearings ensuring years of reliable operation.

Model WX Hot Crimp Welder is a unique machine for bonding, welding, or reflowing tubular-shaped plastic assemblies.

The welder consists of a variable-diameter hot-die mechanism designed to have minimal friction, allowing the closed-loop force control to be accurate and responsive, even at very low force levels. An assembly of thermoplastic parts covered by a heat-shrink tube is inserted into the opening and then the dies are closed on to the joint. The mechanism follows the tubing as it shrinks, maintaining direct thermal contact around the whole circumference. This results in repeatable welding temperature and process consistency.  All the motion is guided by precision ball-bearings ensuring years of reliable operation.

Force while welding – dies follow heat-shrink tubing as it shrinks and can apply compression during the bonding process, improving the quality of the bond.

Universal tooling – with a large diameter range virtually all products can be processed with one compression station.

Direct contact heating – temperature is accurately controlled and heat transfers quickly to product.

Heated Dies – Cartridge heaters, temperature sensor, and over-temperature switch are installed in the dies. Recipes contain a heat on / off setting and a temperature setpoint that may range from 0 to 250C.

Recipe Storage –  up to 500 recipes, with 50 steps per recipe. Step advancement by dwell time or button press. Step types include: diameter setting, force setting, cooling air on or off, verify diameter, verify force, and others.

How does the WX Hot Crimp Welder compare to other welding or bonding methods?

  • Split-Die Bonders (Hot-Jaw Bonders) have an opening with a single diameter. They tend to contact the heat-shrink tubing inconsistently after it has shrunk. Also, the tooling (dies) is not universal and must be changed for different products.
  • Hot Air Systems (Hot Boxes) blow air from a nozzle at a much hotter temperature over the weld joint. Temperature of the bond is difficult to control because of variability from air flow and convective heat transfer. Uniformity of temperature around the joint is also problematic due to the directionality of the nozzle air flow.
  • Laser Bonders (Laser Welders) are power-controlled devices wherein slight variations in delivered power can cause large variations in the product’s temperature.
By contrast, the WX Hot Crimp Welder (Radial Compression Bonder) applies tightly controlled temperature encircling the entire bond. It transfers the heat quickly through conduction even as the product shrinks. It applies external force during the welding process, which is unique to the Blockwise machine. With the WX, one welder can accommodate virtually every diameter product.
The touch-screen based machine controller is powerful and intuitive. Recipes are easily crafted by creating a sequence of steps with the operator interface. Manual mode allows direct commands without a recipe. Recipe editing, calibration, and manual operation mode may be password-protected.

Calibration or checking of diameter and force is very quick and easy. Only one pin is needed for diameter. Calibrating the diameter does not necessitate a force recalibration, or vice-versa. Checking or calibration of pressure or temperature requires customer-supplied reference instruments

The WX requires no maintenance – just keep the mechanism clean. You may clean the mechanism by blowing with compressed air. You may clean the center opening with 99% isopropyl alcohol on a lint-free swab or cloth.

Required Installation Connections – Model WX
Description Physical Specs Functional Specs
Electric Power Powers the control system, HMI, motors, etc. C13 Coupler (IEC 60320) 100-240 VAC 6A 50-60Hz
Compressed Air Powers the Simpluer connector, etc.
(see Knowledge Base: Compressed Air &
High Pressure Gas Connections)		 Instant Tube Fitting Accepts ¼-inch OD Plastic Tube 6.9 to 8.3 bar (100 to 120 psi)

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  • Model WX with RWE Station

    Weld plastics by applying heat and radial compression. Precision-built, low-friction radial compression mechanism is designed for maximum reliability. Closed-loop diameter and force control guarantee optimum repeatability. Step-based recipe control allows for flexible processing.

    Diameter LengthMax Radial ForceMax Temp RatingDie Material
    0 - 30 mm 1, 1.5, 2, 2.5, 3, 4, 5, 6.3mm, custom 133 N 260 C Hardened Stainless Steel