Understanding Plastic Welding Processes and Choosing the Right Tools for the Job
Not All Plastic Welding Jobs Use the Same Tools
Every welding method requires different tools.
Different materials, varying thicknesses, and even tight or awkward job-site conditions all dictate which welding process should be used and which machine is suitable.
BAK Switzerland designs equipment to support every major plastic welding process, from compact handheld hot air tools to fully automatic production-line welders.
Heres a clear breakdown to help you match each welding method with the right BAK machine.
1. Automatic Hot Air Welding
For long, clean, consistent seams
Automatic hot air welding uses precisely controlled hot air to melt two layers of material while a pressure roller applies even force to create a strong overlap seam.
Its ideal for applications requiring long, smooth, weather-resistant welds.
A hot air nozzle delivers focused heat to the joint, while the pressure roller compresses the layers together. This technology is widely used in roofing, waterproofing, and industrial fabrics.
Recommended Models:
- BAK RoofOn / LarOn21 PVC & TPO roofing systems
- BAK PlanOn Industrial fabrics, tarpaulins, and banner materials
For heavy-gauge materials requiring maximum strength
Hot Wedge Welding is a high-efficiency process designed specifically for thicker geomembranes.
A heated metal wedge powered by cartridge heaters melts the material directly while applying high pressure to achieve a dense, durable weld.
This results in exceptional tensile strength, making it suitable for heavy-duty civil engineering applications such as geomembranes, reservoirs, and containment structures.
Recommended Models:
- BAK ComOn2 HDPE 1.03.0 mm
- BAK ProtOn Wedge HDPE 0.51.5 mm
3. Hot Air Wedge Welding
Wedge-level strength with the versatility of hot air
This method is an evolution of traditional wedge welding.
Instead of a metal hot wedge, it uses a hot air nozzle, giving similar welding performance but with far better compatibility across different materials such as PE, PVC, PP, ECB, EVA, and TPO.
Metal wedge systems cannot weld PVC directly (PVC fumes corrode copper wedges), but hot air systems avoid this issue entirely.
Hot Air Wedge Welding is engineered for tunneling applications, especially for PVC or TPO waterproofing membranes requiring structural-grade seams.
Recommended Models:
- BAK ProtOn HDPE 0.31.5 mm, PVC 0.51.5 mm
The classic, all-purpose method every technician needs
Even with the rise of automation, handheld hot air tools remain essential on every job site.
They are versatile, portable, and compatible with most thermoplastics including PVC, PP, PE, ABS, and more.
Hand welders are perfect for beginners and professionals alike easy to use, reliable, serviceable, and capable of reaching tight spaces. With interchangeable nozzles, they handle repairs, detailing, fabrication, and fieldwork effortlessly.
This is the universal must-have tool in every technicians kit.
Recommended Models:
- BAK RiOn Robust, easy to use; ideal for general applications
- BAK RiOn Digital Precise digital temperature control for QC-critical jobs
- BAK MarOn Slim grip, lightweight; perfect for confined spaces
- BAK LiiOn Cordless; ideal for sites without power access
5. Extrusion Welding
Structural-strength welding for tanks, pipes & heavy fabrication
If hot air welding is the foundation of plastic welding, Extrusion Welding is the next level.
Extrusion welders melt a plastic welding rod inside the tool, turning it into molten material that is pushed through an extrusion nozzle onto a pre-heated seam.
Heat from the molten filler and the hot air preheat combine to fuse both sides into a single, extremely strong joint.
This produces welds capable of withstanding high pressure and structural loads.
Extrusion welding is essential for:
- Large-scale fabrication
- Chemical tanks
- Industrial pipes
- Water & chemical storage systems
- Any application requiring maximum seam strength
