Vibration welding uses heat generated by friction at the interface of two thermoplastic parts to produce melting in the interfacial area. The molten materials flow together under pressure and bond, forming a weld upon cooling.

Vision systems used to guide robots pose different challenges for manufacturers than vision systems used for part inspection. The biggest challenge is guiding robots in 2-1/2D applications, where guidance is used so the camera maintains a proper perspective of a part that is level but included in a stack.

Green lasers are a viable method for welding thin copper parts in high-volume applications.

Thermal joining processes play a key role in solar panel assembly.

Inspired by nature, engineers are developing new gripper technologies that promise to make robots more flexible.

Several manufacturers consider electromagnetic, or induction, welding a better way to weld highly filled thermoplastics than thermal or friction welding, or using adhesives.

In the future, the “smartest" form of assembly may be no assembly at all. That’s the goal of additive layer manufacturing.

Automakers are often the driving force behind the latest product and process innovations in assembly. Case in point: European automakers have been using flow drilling screws since 1996 to assemble body panels and chassis made of aluminum and thin materials-which continue to gain favor to make cars lighter.

Traditionally, manufacturers have relied on manual welding to assemble high-mix, low-volume products. But, more companies are turning to a new breed of flexible robots, software and controls.

Whether joining two wires together or attaching multiple wires directly to a terminal or assembly, engineers must choose between resistance welding, soldering and ultrasonic welding.