Innovative Plastic Seating Stool

The Plastic Welding Challenge

A furniture manufacturer developed an innovative seating stool that provided several consumer benefits but demanded unique manufacturing considerations. Initially, they used adhesives to join the upper and lower domes to the narrow center. However, adhesives introduced serious drawbacks. Adhesives themselves were costly, the application was messy and inconsistent, they required long cure times that slowed production, and the final product failed to meet long-term durability standards.

The Innovative Seating Stool Required:

• Airtight seals with zero pressure decay over 100,000 test cycles.
• Structural strength and long-term durability.
• Large-diameter weld lines.
• Three separate weld lines totaling more than 80”.
• Reliable joining of dissimilar filled materials: Talc-filled polypropylene (PP) to thermoplastic vulcanizates (TPV).

The Emabond Solution

Emabond’s unique material and welding technology were able to deliver the high-strength weld where no other joining process could. By using our electromagnetic welding technology combined with specially blended Emabond material, we successfully joined talc-filled PP to TPV, two dissimilar materials that adhesives could only temporarily bond. The process created three large-diameter welds with consistent airtight seals, something ultrasonic or vibration welding couldn’t achieve. In addition, by eliminating adhesives, the manufacturer reduced material costs and eliminated cure time, streamlining production efficiency.

Tangible Results with Cost-Saving Benefits:

• Airtight Reliability: Welds maintained zero pressure decay over 100,000 test cycles, ensuring long-term durability and unmatched product performance.
• Dissimilar Material Bonding: Produced high-strength welds between talc-filled PP and TPV with bonds stronger and longer-lasting than adhesives.
• Geometry Flexibility: Delivered consistent welds across three separate large-diameter seams, totaling more than 80”.
• Production Efficiency: Eliminated adhesives and cure time, cutting costs and accelerating manufacturing throughput.

Emabond’s Lasting Impact

Emabond material is specially formulated to join dissimilar materials in a fraction of the time that adhesives take, leaving cleaner, more reliable welds capable of remaining airtight under daily use. These durable, airtight welds helped transform the innovative seating stool into a product that exceeds performance expectations and stands up to demanding lifecycle testing. The solution not only ensured durability but also created a more cost-efficient and scalable manufacturing process, laying the groundwork for long-term product success.

Dissimilar Material Welding Is Possible With Emabond

When adhesives fall short, Emabond delivers the airtight, high-strength welds you need, even across dissimilar materials and complex, large-diameter geometries. Our process eliminates cure-time delays, reduces costs, and is designed to solve the toughest plastic joining challenges.

Contact Emabond today to learn how we can solve your toughest challenges.