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The technique applied in plastic welding is just about like what is used in spot welding. The only difference is that heat is transferred through pincher tips in plastic welding instead of electrical conduction. The two pieces of plastic are placed together and heat tips are used to pinch them, which melts the plastic causing them to join. Plastic welding involves applying a jet of hot air, which melts the pieces with plastic filler rod. The melting rod is forced into the joint and amalgamated to the parts.

The first main point to consider when welding the plastic is to correctly identify the type of the plastic so that you can select a proper welding rod. A plastic or thermoplastic welding rod that has a constant triangular or circular cross-section is used to join the two parts of plastic with each other. Porosity is an important thing to consider when it comes to plastic welding rod. Air bubbles are formed in a high porosity rod that reduces the quality of the weld. That’s why, it is important to use rod with zero or negligible porosity.

Before beginning plastic welding you have to be aware of the surroundings. The work area should have to be clean and properly ventilated. When using the welder, beware that it is quite hot and can inflict burns or even cause fire to break. Always keep it on the stand while pre-heating. Put the parts to be weld together and apply the alumni tape to keep them in place. If the surface of the parts is painted, remove the paint from the region where weld is to be applied by using sandpaper. Use grinder to make a V shaped groove at the place to be welded. Place the tip of the welder on the area and move the welder backwards or towards yourself to clearly see the rod filling the groove while you make the pass. Before the melting rod turns cold, apply the hot tip of the welder on the same spot in order to thoroughly fuse the melting rod with the base material to get a clean weld. To get a fine blend, proper heat should be maintained. If it needed, wire mesh can also be added into the area to be repaired for extra support. The only thing to take care is that it should be properly covered by the plastic. Extra care should be taken when welding thin material to avoid melting a hole through it. Once the welding is completed on the one side, apply the same process for the other side too. After the joint cools down, use coarse sandpaper first, followed by a finer grade in order to grind the weld down. Turn off the welder and put it into the holder and allow it to cool down.