Emabond: Insulated Coolers

Delivering Leak-Proof, Lightweight Coolers with Advanced Plastic Welding

The Plastic Welding Challenge

A leading insulated cooler manufacturer wanted to move beyond rotational molding and glue, which limited design possibilities, increased costs, and added unnecessary weight. The market demanded highly aesthetic products durable enough to withstand rugged outdoor adventures and highly efficient at keeping contents cold. However, traditional roto-molding and hot plate joining processes created thick walls, distortion, and limited insulation options, making it difficult to meet both performance and visual quality expectations.

The Insulated Coolers Required:

Clean, distortion-free welds.
Large three-dimensional geometries.
Leak-proof durability and bear-resistant performance.
Thin wall sections under 2 mm for material efficiency.
Greater use of insulating foam for longer cold retention.
Highly aesthetic, customer-ready finishes.

Emabond’s Plastic Welding Solution

Emabond plastic welding technology enabled this customer to switch from rotational molding to injection molding while improving production quality and durability. Using specially formulated polypropylene welding materials, Emabond created strong, flash-free joints in weld lines up to 16 feet long. Switching to injection molding reduced wall thickness and material usage while allowing more foam insulation to improve thermal performance. At the same time, injection molding offered improved repeatability, higher-quality finishes, and faster, more efficient production cycles compared to roto-molding.

Tangible Benefits with Lasting Results

Cost Savings: Less plastic and faster cycles lowered material and production costs.
Higher Production Efficiency: Injection molding enabled scalable, high-volume output.
Superior Insulation: Increased insulation capacity improved thermal performance, keeping contents colder for longer.
Lighter & Stronger: Thin-walled designs with welds under 2 mm, increased portability without sacrificing durability or leak-proof reliability.
Enhanced Finish: Injection molding improved surface finishes, while clean and aesthetic welds elevated customer appeal.
Design Flexibility: Complex, three-dimensional geometries can be manufactured consistently and reliably.

Emabond’s Lasting Impact

By replacing rotational molding with Emabond plastic welding and injection molding, this manufacturer solved immediate design, cost, and quality challenges while improving product performance and consumer appeal. The new process produced lighter, stronger coolers with extended insulation capabilities and enhanced aesthetics while also increasing production efficiency and repeatability. As a result, the customer has gradually transitioned their entire cooler line to Emabond technology.

Emabond is Plastic Welding at Its Finest

Experience unmatched precision, strength, and efficiency with the leading solution for bonding high-strength, complex thermoplastic parts. Emabond delivers superior results where other methods fall short.