Tool for melting plastic stub fixing?

Jan 19, 2026 Last reply: 5 months ago 25 Replies

I'm looking for a tool to "melt" those plastic stub/peg fixings that poke through PCB holes to give mechanical strength to large items, or hold non-electrical things like light guides in place.



For a quick bodge I just use the standard soldering bit in a Weller heat gun, but that always looks messy and probably isn't very secure, see the two black blobs on this:



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I was hoping there would be a suitable bit for the Weller, with a concave tip like this, but can't see anyting suitable:


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I suppose I could mod a normal bit to be hollow, but how are these things normally done (ultrasonics?)



I may have several hundred to do...



Even the cheapet gear seems to manage self-tapping screws for this kind of mechanical security, these days.

RL

It's outside my experience - but apparently it's called Thermal Staking, and does indeed use ultrasonics in a factory situation.

There do seem to be a few DIY options - see

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nothing specifically for your Weller

It would be easy to glue them, like with a UV-cure adhesive.

John Larkin Highland Tech Glen Canyon Design Center Lunatic Fringe Electronics

Dab of hotSnot™

Try that and let us know how it works.

I had in mind Bondic or an eqivalent. Use a UV flashlight, not the dinky blue LED that comes with it. Dab and flash in maybe 8 seconds.

John Larkin Highland Tech Glen Canyon Design Center Lunatic Fringe Electronics

Ta. Glue of some kind is a good suggestion. Will do some experiments.

Thanks for the search term, I had no idea what it was called :)

Press fit into oval holes.

John Larkin Highland Tech Glen Canyon Design Center Lunatic Fringe Electronics

Press fit does not work for plastics except delrin - the stress causes other plastics to crack and fracture.

Joe

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pertains to a DIY tip for a Weller. It looks easy enough.

One professional product's pricier than a piece of copper wire from your junk drawer:

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Usually, they nestle into structures created to hold them where intended.

Yes. Or, see below.

These then become disposable items? No real chance of repair? (as long as you think that appropriate...) I consider my enclosures to be discardable but replaced at the depot (reusing the "guts")

Screws? Mechanically clamping it in place with a boss extending from the other half of the enclosure?

That depends on how hard you squeeze it.

John Larkin Highland Tech Glen Canyon Design Center Lunatic Fringe Electronics

Buy 'starlock washers' from Ebay etc. Push on, don't come off- so long as you use the right diameter- not hard if going over a plastic 'stud'.

I have used ty-ribs ...

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Hotglue is also magic stuff to fixate things, you need a special 'iron' for that. Only a few dollars from ebay.

Yep, it's just thick copper wire/rod with a thinner bit as the "tip".

That's the sort of thing I was expecting to find, so it can be done that way.

Ouch (and that's just the stand!)

Sounds fiddly, especially if the studs are short, but added to the list of options...

Maybe. I'd be worried about them working loose after a while (there will be some mechanical stress).

Repair would be to cut off the fixings with side-cutters / scalpel, desolder and replace (it's for components, not the case).

It's for keyboard switches, which are a given, so I have to work with what they are.

Then you likely want something that is repeatable. Using a "random heating element" would likely result in too much variability.

My bad. I see you stated effectively that in your original post. :<

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