In 2026, AMD Machines quoted a plastic staking station at $150,000–$190,000 for the station alone and $160,000–$200,000 with shipping and five days of commissioning. The station secures a PA6 plastic plate and a metal plate to a molded plastic part by staking six ABS plastic poles, four by ultrasonic staking and two by heat staking, on a two-position rotary index table.
This case study breaks the AMD Machines quote down line by line. The same station concept fits molded plastic assemblies whose posts hold a plastic or metal component: vehicle interior trim, appliance control panels and covers, electronics housings that capture a circuit board, and consumer product housings. Prices are ranges from AMD Machines' 2026 quote.
A plastic staking station is a machine that melts and reforms plastic posts protruding through a mating part into rivet-like heads that hold it without screws, clips or adhesive; the AMD Machines station in this 2026 case study combines ultrasonic and heat staking.
Staking is sometimes called plastic riveting. For the plastic joining systems AMD Machines builds, see ultrasonic and thermal joining systems.
| Item | AMD Machines staking station |
|---|---|
| Part family | A molded plastic part with a PA6 plastic plate and a metal plate held by six ABS plastic poles |
| Machine | One staking station with a Weiss two-position rotary index table |
| Staking points | Six poles: four ultrasonic, two heat staked |
| Design cycle time | About 45 seconds per part (1.33 parts a minute), from simulation |
| Price | $150,000–$190,000 for the station; $160,000–$200,000 with shipping and five days of commissioning, in US dollars, taxes excluded |
| Lead time | 16–18 weeks, depending on AMD's workload |
What Is in a Combined Ultrasonic and Heat Staking Station?
The AMD Machines combined ultrasonic and heat staking station stakes six poles with two processes on one mechanism: four Herrmann VE35 actuator units for ultrasonic staking and a PID-controlled heat-staking system with two heads.
| System | Equipment in the AMD Machines station |
|---|---|
| Ultrasonic generators | Two Herrmann AMG 1200 MX Ultraplast generators with EtherNet/IP |
| Ultrasonic staking units | Four Herrmann VE35 actuator units with Herrmann KHS35 converters and CPM sonotrodes at 35 kHz |
| Heat staking | Two heat-staking generators with PID temperature control driving two heads on two pneumatic cylinders; two tips per head, with heating cartridge and thermocouple kits |
| Index table | Weiss two-position rotary index table with a variable frequency drive |
| Fixture | Custom fixturing on an aluminum index plate, with a pneumatic fixture lifter |
| PLC and HMI | Siemens S7-1200 PLC with its modules in the main cabinet; Siemens MTP700 Unified Basic HMI in a small secondary cabinet |
| Sensors and I/O | IO-Link master and slaves; part-present sensors; magnetic cylinder sensors; HID proximity card reader |
| Pneumatics | Filter-regulator-lubricator unit, valve manifold and cylinders |
| Frame and guarding | Welded steel frame with base plate and leveling pads; aluminum-profile guarding with panels; polycarbonate window; safety door for maintenance and service, with interlocks |
| Status | Multicolor light tower; station lamp |
How Much Does a Plastic Staking Station Cost?
In a 2026 AMD Machines quote, a combined ultrasonic and heat staking station costs $150,000–$190,000 for the station alone and $160,000–$200,000 with shipping and five days of commissioning. AMD Machines prices it in US dollars, taxes excluded.
| Line in the AMD Machines quote | Price range |
|---|---|
| Staking station alone | $150,000–$190,000 |
| Shipping with insurance to the buyer's plant (optional) | Under $5,000 |
| Commissioning, 5 days | $6,000–$8,000 |
| Total with shipping and commissioning | $160,000–$200,000 |
How Does This Two-Process Staking Station Compare With a Standalone Ultrasonic Station?
In the 2026 AMD Machines quote, the two-process staking station, at $150,000–$190,000 for the station alone, starts where the $75,000 to $150,000 range AMD Machines publishes for a standalone ultrasonic welding station ends; it carries two staking processes, six staking points and an index table. The AMD Machines thermal joining systems page says: "A standalone ultrasonic welding station with servo actuation, process monitoring, and safety guarding typically runs $75,000 to $150,000 depending on complexity. Multi-station systems with robotic loading, vision inspection, and leak testing can range from $250,000 to $750,000+." The station sits below that multi-station range, with no robotic loading, vision inspection or leak test.
The AMD Machines guide to what automation costs says simple single-station cells ("one press-fit, one screwdriving operation, basic verification") "start from ~$100K." This two-process station sits well above that floor.
What Are the Payment Terms for a Staking Station?
AMD Machines splits payment for the staking station across four milestones: 40% with the purchase order, 30% at design approval, 20% at approval at AMD's plant and 10% at approval at the buyer's facility.
What Moves the Price of a Staking Station?
Five choices move the price of a staking station most, and the AMD Machines station sets them as follows:
| Cost driver | In the AMD Machines station | How it moves the price |
|---|---|---|
| Staking points | Six poles: four ultrasonic, each on its own Herrmann VE35 unit, two heat staked | Added poles usually add tooling |
| Process per pole | Ultrasonic for the four poles holding the PA6 plate; heat staking for the two poles holding the metal plate | Two processes mean two sets of tooling, each with its own controls; one process usually costs less |
| Part presentation | Two-position index table with a lifting fixture | Usually costs more than a fixed nest, and gives a load position away from the tooling |
| Component brands | Siemens PLC and HMI, Herrmann ultrasonics, Weiss index table | A plant's own required brands can change part of the bill of materials |
| Validation | An empty test, a 300-part production lot or as required, and a checklist | Requirements beyond the standard run-off can add cost |
Why Does One Staking Station Use Both Ultrasonic and Heat Staking?
AMD Machines' engineering team assigns one joining method to each of the part's two plates: ultrasonic staking for the four poles that hold the PA6 plastic plate, and PID-controlled heat staking for the two that hold the metal plate. For a new part, AMD Machines chooses each pole's process based on the part's geometry and the materials of the part and its components, and confirms it in trials on sample parts.
AMD Machines mounts the ultrasonic and heat-staking tooling on one mechanism, which a pneumatic cylinder moves to a single process position over one fixture, so the part is located once for all six poles.
Why Put a Staking Station on a Two-Position Rotary Index Table?
A two-position rotary index table lets a staking station be loaded away from its process position, clear of the heated tips and vibrating sonotrodes. On the AMD Machines station, parts load at one position of the Weiss table and are staked at the other, behind guarding with a polycarbonate window.
Can a Staking Station Use Your Plant's PLC, Safety and Pneumatics Brands?
Yes. For this staking station, AMD Machines asks for the plant's PLC, safety and pneumatics standards so the machine is quoted to them, and offers AMD's standard components otherwise. Asking first avoids requoting a machine after the plant's maintenance team reviews it.
How Does a Staking Station Work, Step by Step?
AMD Machines bases the staking station's design cycle of about 45 seconds per part, or 1.33 parts a minute, on simulation results. The cycle runs in five steps:
- Load. The molded part, with both plates in place, is loaded into a custom fixture on the table's aluminum plate at the load position.
- Index. The Weiss table carries the part to the process position.
- Position. Pneumatic cylinders lift the fixture from below to position the part and move the combined staking mechanism into the process position.
- Stake. The four poles holding the PA6 plastic plate are staked ultrasonically, and the two poles holding the metal plate are heat staked.
- Return and unload. The table indexes back to the load position, and the finished part is unloaded.
Which Parts and Industries Does This Staking Station Fit?
AMD Machines' staking station concept suits molded plastic assemblies sized for one fixture on a two-position index table, whose posts pass through a plastic or metal component:
| Part family | Why it fits | What would change |
|---|---|---|
| Vehicle interior trim and console parts that carry brackets, clips or reinforcement plates | Molded plastic posts capture a plastic or metal component | The fixture nest; the number and layout of sonotrodes and heated tips for the part's pole pattern |
| Appliance control panels, covers and trim that hold a metal bracket, a lens or a control board | The same post-through-component joint on a molded plastic part | A fixture and index plate sized to the panel; tooling for its pole count |
| Electronics housings and covers that capture a circuit board or a metal bracket | Staking holds the component without screws, clips or adhesive | A nest that supports the board; process trials on sample parts |
| Consumer product and power-tool housings that hold a metal plate, a grille or a badge | Molded posts pass through a plastic or metal component | Stake profiles for cosmetic surfaces; the fixture; the cycle time for the pole count |
| Molded parts whose posts all take one process | The index table, fixture lifter and controls still apply | One set of tooling and its controls drops out; one process usually costs less |
For these industries, see AMD Machines' automotive manufacturing automation, appliance manufacturing automation and electronics manufacturing automation pages.
What Safety Equipment Does a Staking Station Need?
AMD Machines safeguards the staking station with safety light curtains, aluminum-profile guarding with a polycarbonate window, two safety magnetic interlocks on the service doors, two emergency stops (one at the worktable, one at the secondary cabinet) and two safety relays. In your request for quote, specify UL 508A for the control panel, NFPA 79 for the electrical equipment and an assessment of the safeguarding against the ANSI B11 machine safety standards.
What Does a Staking Station Quote Include and Leave Out?
The AMD Machines quote for the staking station includes design, manufacturing, debugging, programming, validation at AMD's plant in Querétaro, Mexico, documentation and a 12-month warranty; taxes, part data and samples and, without the shipping option, freight are the buyer's.
| Item | In the AMD Machines quote |
|---|---|
| Design, manufacturing, debugging and programming | Included |
| Validation at AMD's plant | Included: an empty test, a production lot of 300 parts or as required, and a checklist |
| Manuals and documentation package | Included: two digital copies and one printed copy |
| Warranty on parts AMD builds | 12 months, valid once the machine is paid for |
| Warranty on bought-out components | Their suppliers' warranties |
| Freight without the shipping option | Buyer, since the station price stops at AMD's plant |
| Taxes | Buyer; not included |
| Part drawings, 2D and 3D files, sample parts | Buyer |
| Changes after an order is placed | Quoted separately |
How Long Does It Take to Build a Staking Station?
AMD Machines' lead time for the combined ultrasonic and heat staking station is 16 to 18 weeks, depending on AMD's workload when an order is placed, followed by the optional shipping and five days of commissioning.
AMD Machines delivers simple machines in as little as 6 weeks and complex systems in 24–26 weeks, vs. 40–42 weeks typical for overseas builders. This station's 16 to 18 weeks sits between those ranges. The AMD Machines guide to custom automation lead times explains what sets the schedule.
What Should You Send to Get a Staking Station Quoted?
To get a staking station quoted, send AMD Machines your part and component data, sample parts, and your production and plant requirements:
| What to send | Why AMD Machines needs it |
|---|---|
| 3D models and 2D drawings of the part and every captured component, with each pole marked | Sets the pole count, fixture and tooling |
| Material of the part and of each captured component | Guides the process for each pole |
| Sample parts and components | Trials to confirm each pole's process |
| Target cycle time, annual volume and shifts | Sizes the station |
| Loading method: a person at the station or an automated line | Sets the part presentation |
| Plant voltage, phase and frequency, and the electrical and safety standards to build to | Sets the electrical and safety design |
| Fastener standard, inch or metric | Sets the screws AMD Machines specifies |
| Preferred brands for PLC, HMI, ultrasonics, pneumatics and safety | Fixes part of the bill of materials |
| Validation, documentation, freight and commissioning needs | Sets the scope lines of the quote |
If the staking station will sit in a line, the AMD Machines page on custom automated assembly machines covers multi-station rotary, linear and robotic machines that choose a joining method per station.
Staking Station FAQ
How much does an ultrasonic and heat staking machine cost?
An ultrasonic and heat staking machine costs $150,000–$190,000 for the station alone and $160,000–$200,000 with shipping and five days of commissioning in a 2026 AMD Machines quote for a six-pole station on a two-position rotary index table, in US dollars, taxes excluded.
What is the difference between ultrasonic staking and heat staking?
Ultrasonic staking melts a plastic post with high-frequency vibration from a sonotrode, 35 kHz on this AMD Machines station, while heat staking melts it with heated tips in direct contact, held at temperature by a controller. Both reform the post into a head that captures the mating component. For process detail, see the AMD Machines guides to ultrasonic joining of plastics and the heat staking process.
What cycle time is a staking station designed for?
AMD Machines designs this six-pole staking station for about 45 seconds per part, or 1.33 parts a minute, based on simulation results. Cycle time depends on the pole count, the process for each pole and how the part is loaded, so AMD Machines sizes each station to your part and target cycle time.
If you're budgeting a staking machine for molded plastic parts, send your part and components to request a staking station quote, and AMD Machines will tell you which process fits each pole and what the station costs.