A man using a plastic welder to weld two pieces of plastic togeher

How to Weld Plastic With a Plastic Welder

Welding is a simple solution for repairing cracks or connecting plastic parts. With an electric welding gun and rod, the process can be done at home. The method involves pressing surfaces, applying heat and pressure, and then smoothing the weld for durability.

What Is Plastic Welding?

Plastic welding is a widely used method that involves joining two thermoplastics together at the molecular level. Plastic welding involves three steps: pressing the materials together, heating them, and then cooling them down. This process creates a highly durable bond between the materials.

How To Weld Plastic: The Essential Steps

Welding gloves used to weld plastic

Step 1: Set up the working space and clean the plastic

Before we delve into any welding project, the first thing we need to make sure of is to set up our working space. We need to make sure that we put on protective gear and work in a well-ventilated space.

A man joining plastic with a plastic welder

Step 2: Joining the Plastic

Heating the welding gun takes around 2-3 minutes. I suggest that you preheat the welding gun and set your welding temperatures correctly. The recommended temperature for Polyvinyl Chloride (PVC) is 275°C while for polyethene (PE) is set at 265 °C. Here is an instructional video on how to do it properly: Timestamp at 5:15 – 6:15 

Sand paper for plastic welding

Step 3: Complete the weld and sanding

To ensure proper plastic welding, it is important that the plastic is securely fixed in place before it completely cools down. Afterward, allow the plastic to cool down for approximately 5 minutes before proceeding with sanding. It is important to ensure that the plastic has reached a near-zero temperature to facilitate a seamless sanding process. By following these easy steps, you can successfully perform plastic welding.

How To Weld Plastic: 5-8 Methods

Ultrasonic Welding

Ultrasonic welding is a technique used to join two materials using high-frequency ultrasonic acoustic vibrations.  We use this method commonly in the manufacturing of plastics, including packaging, plastic toys, and automotive parts.

Laser Welding

Laser plastic welding is a joining process that uses a laser beam to melt and fuse together two plastic parts. The process is commonly used in the automotive, medical, and electronics industries for joining plastic parts that are difficult or impossible to join using traditional methods like glue, and screws.

Friction Welding

Friction welding is a process that involves holding one of the plastic parts stationary while the other is rotated against it, creating friction between the two parts. It is commonly used in manufacturing a variety of products including electrical connectors, thermoplastics, and household appliances.

High-Frequency Welding

High-frequency welding is a fast and efficient process that is ideal for producing large quantities of products. This technique we use produces high-frequency electromagnetic waves to heat and join material together such as inflatable toys, raincoats, and tents.

Vibration Welding

Vibration welding can be used to join a variety of plastic materials, including polypropylene, polyethylene, and nylon. In this technique, we clamp two plastic parts together and then vibrate one part against the other, causing heat up that creates a weld. 

Hot Plate Welding

We use this technique to join two thermoplastic parts together by heating them on a hot plate. When it softens, we press them together under pressure to create a weld. This method we commonly used on plastic parts, and consumer goods.

Hot Gas Welding

Hot gas plastic welding involves heating the plastic parts to their melting point using a hot gas stream and then pressing them together to create a strong bond. Hot gas welding is commonly used in the fabrication of plastic tanks, containers, and pipes. 

Spin Welding

Spin welding is a solid-state welding technique used to join thermoplastic parts together by spinning one part at a high speed and pressing it against another part that is held stationary. Spin welding is used for medical devices, and water filters.

Things You’ll Need

Plastic welding gun

We use plastic welding guns for joining and repairing thermoplastic materials. This tool is available in various sizes and types to accommodate different types and welding requirements.

Plastic welding machine

Plastic welding machine

A plastic welding machine is a tool that we use to join or repair thermoplastic materials. It works by heating and melting the plastic, which then cools and solidifies, creating a strong bond between the materials. We use plastic welding machines for welding pipes, tanks, automotive components, and electronic enclosures.

Plastic welding rod

A plastic rod is a solid cylindrical object made of a thermoplastic material that we used especially for welding. This rod is available in different shapes, sizes, and colors, depending on the specific application.  

Plastic welding staples

plastic welding staples

We use plastic welding staples to reinforce and repair thermoplastic materials. These staples are small, U-shaped plastic pieces that are inserted into the plastic material using a plastic welding machine.

Plastic weld glue

Plastic weld glue

Plastic weld glue, also known as plastic welding adhesive, is a type of adhesive used for bonding and repairing thermoplastic materials. We use this material for plastic welding applications including boat repair, automotive repair, and plastic product manufacturing.

In conclusion, welding has had a significant impact on the world by enabling the creation and repair of a vast range of products made of different materials, including plastic. Plastic welding, in particular, has revolutionized the plastic industry by providing a permanent bonding solution for plastic components, leading to the development of new and innovative products.


How effective is plastic welding?

Plastic welding is a highly effective bonding method we use for joining and repairing plastic components. When done properly, we can create a permanent bond that is stronger and more durable than adhesives or mechanical fasteners.

How do you prepare plastic for welding?

  • We need to make sure that the surface to be welded is clean and free of dirt, debris or oil.
  • The next step is to roughen the surface with sandpaper or a rotary brush to ensure our welding rod can adhere to it.
  • Make sure that the plastic pieces are held firmly in place.
  • Lastly, we need to make sure that the welding rod we use matches the type of plastic being welded.

How do you use a plastic staple welder?

We use a plastic staple welder by melting and pressing a plastic staple onto the parts being joined. We need to follow the manufacturers’ instructions and safety precautions when using this tool to ensure a successful weld and prevent injury.

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