Standard 3mm, 4mm and 5mm round welding rod covers many thermoplastic fabrication jobs, but industrial applications frequently require something different. A project may need a specific resin, unusual diameter, triangle profile, custom color, special spool configuration or a welding rod matched to an existing product.
Working directly with a plastic welding rod manufacturer makes it possible to develop the filler around the application rather than forcing the application to use an unsuitable standard product.
Custom Plastic Welding Rod Capabilities
Custom Materials
Welding rod can be developed using suitable customer-specified thermoplastic resins or selected materials for a particular welding application.
Custom Colors
Welding rod colors can be developed to coordinate with sheet, tanks, fabricated components or customer product lines.
Custom Diameters
Diameters outside standard 3mm, 4mm and 5mm sizes can be evaluated for manufacturing.
Custom Profiles
Round, triangle and specialty cross-sectional profiles can be developed for specific welding and fabrication requirements.
Custom Packaging
Spool, bulk and customer-specific packaging requirements can be evaluated.
Private Label & OEM
Welding rod can be manufactured for distributors, equipment companies and OEM customers under private-label programs.
Custom Welding Rod Materials
Custom thermoplastic welding rod can be produced in a variety of materials depending on the application.
| Material | Common Search Name | More Information |
|---|---|---|
| HDPE | Custom HDPE welding rod | HDPE Welding Rod |
| Polyethylene | Custom polyethylene / PE welding rod | Polyethylene Welding Rod |
| Polypropylene | Custom PP welding rod | Polypropylene Welding Rod |
| PVC | Custom PVC welding rod | PVC Welding Rod |
| PVDF | Custom PVDF welding rod | PVDF Welding Rod |
| ABS | Custom ABS welding rod | ABS Welding Rod |
| PETG | Custom PETG welding rod | PETG Welding Rod |
| TPU | Custom TPU welding rod | TPU Welding Rod |
Custom Polyethylene Welding Rod
Polyethylene is available in multiple material families and grades. Custom PE welding rod can include:
- LLDPE welding rod
- LDPE welding rod
- MDPE welding rod
- HDPE welding rod
- HMWPE welding rod
When possible, provide the actual resin grade or detailed information about the parent polyethylene being welded.
Custom HDPE Welding Rod
Custom HDPE welding rod can be produced when a fabricator or OEM needs more than a standard natural or black round filler rod.
Custom HDPE requirements can include:
- specific resin grades
- custom colors
- nonstandard diameters
- triangle profiles
- specialty cross sections
- specific spool configurations
- OEM packaging
HDPE welding rod is commonly used in tank fabrication, thermoplastic sheet fabrication, liners, containment products and industrial plastic repair.
Custom Polypropylene Welding Rod
Custom polypropylene welding rod can be produced for customers requiring a particular PP material, size, color or profile.
Applications can include:
- polypropylene tanks
- PP sheet fabrication
- ductwork
- chemical process equipment
- industrial fabrication
- OEM products
Polypropylene can be supplied as homopolymer, copolymer and modified formulations, so the exact material requirement can be important.
Custom PVC Welding Rod
PVC welding rod can be customized for suitable rigid and flexible PVC applications.
Possible custom requirements include:
- rigid PVC welding rod
- flexible PVC welding rod
- custom colors
- custom diameters
- special profiles
- customer-specific packaging
Because PVC formulations can contain different plasticizers, stabilizers, fillers and pigments, provide as much information about the parent PVC as possible.
Custom PVDF Welding Rod
PVDF is used in specialized industrial applications where resin grade and material consistency can be especially important.
For a custom PVDF welding rod request, useful information includes:
- PVDF resin grade
- parent sheet or component manufacturer
- required rod diameter
- required profile
- color
- quantity
- application requirements
Custom ABS Welding Rod
Custom ABS welding rod can be manufactured for compatible ABS fabrication and repair applications.
Because commercial ABS materials may differ in composition, grade and modification, identifying the actual parent material is preferable to selecting filler only by appearance.
Custom PETG Welding Rod
PETG welding rod can be produced for compatible PETG fabrication, sheet work and specialty applications.
Custom PETG rod can include specialized diameters, colors, profiles and packaging.
Custom TPU Welding Rod
TPU welding rod may be required for flexible thermoplastic applications where hardness and formulation are important.
Useful information for a TPU project includes:
- resin grade
- hardness
- base chemistry where known
- color
- rod dimensions
- application
The term "polyurethane" by itself does not establish that a material is a weldable TPU or that two polyurethane products are compatible.
Custom Color Plastic Welding Rod
One of the most useful custom capabilities is color-matched plastic welding rod.
Visible welds may need to coordinate with:
- plastic sheet
- fabricated tanks
- ductwork
- flooring products
- liners
- equipment housings
- OEM products
- architectural plastic components
How Is Plastic Welding Rod Color Matched?
Depending on the project, color development can begin with:
- a physical plastic sample
- a piece of the parent sheet
- an existing welding rod sample
- a customer-approved color concentrate
- a defined color specification
The goal is to develop the required appearance while retaining the correct thermoplastic base material for the welding application.
Custom Plastic Welding Rod Sizes
Common round welding rod sizes are:
| Rod Size | Approximate Inch Equivalent | Availability |
|---|---|---|
| 3 mm | 0.1181 in. | Common round welding rod size |
| 4 mm | 0.1575 in. | Common round welding rod size |
| 5 mm | 0.1969 in. | Common larger round welding rod size |
| Custom diameter | Customer specification | Can be evaluated for custom extrusion |
See the complete Plastic Welding Rod Sizes Guide .
Custom Diameter Plastic Welding Rod
Some equipment or applications require welding rod outside the common 3mm, 4mm and 5mm range.
A custom diameter may be required because of:
- existing welding equipment
- special speed welding nozzles
- extrusion welder feed requirements
- joint geometry
- required deposition rate
- legacy product specifications
- OEM design requirements
When requesting a custom diameter, provide the actual dimensional requirement and tolerance if known.
Custom Triangle Plastic Welding Rod
Triangle welding rod is commonly used in thermoplastic fabrication, but not every triangle profile is the same.
A triangular profile can be defined by:
- overall width
- overall height
- side dimensions
- included angles
- corner radii
- dimensional tolerances
For this reason, saying only "5.7mm triangle rod" may not completely define the required cross section.
Matching an Existing Triangle Welding Rod
If you already have the welding rod you need, supplying a physical sample can help with profile development.
A dimensional drawing is even more useful when exact geometry and tolerances are important.
Custom Plastic Welding Rod Profiles
Custom extrusion makes it possible to manufacture profiles beyond standard round welding rod.
Depending on the project, possibilities can include:
- round rod
- triangle rod
- modified triangle profiles
- specialty filler profiles
- customer-designed extrusion shapes
Profile feasibility depends on material behavior, dimensions, tolerances and production requirements.
Plastic Welding Rod From Customer-Supplied Material
Some OEM or specialized projects require welding rod made from a particular customer-specified compound.
This may be useful when:
- the parent product uses a proprietary material
- a specific resin grade is required
- the customer already purchases the compound
- special additives are required
- the finished rod must remain tied to an existing material system
Processing feasibility should be evaluated before production because not every compound behaves the same during small-profile extrusion.
OEM Plastic Welding Rod
OEM welding rod can be developed as part of a larger manufactured product or repair system.
OEM requirements can include:
- proprietary material
- specific color
- controlled diameter
- special profile
- customer labeling
- customer packaging
- repeat production lots
This can be particularly useful for companies that manufacture thermoplastic products and want to provide compatible repair or installation welding rod with their products.
Private-Label Plastic Welding Rod
Plastic welding equipment companies, distributors and fabrication suppliers may want to sell welding rod under their own brand.
A private-label program can potentially include:
- selected welding rod materials
- standard or custom diameters
- custom colors
- spool packaging
- customer labels
- customer product identification
- repeat production
Plastic Welding Rod for Distributors
Distributors may need a broader product offering than standard natural HDPE and PP welding rod.
A manufacturer-direct program can provide:
- multiple thermoplastic materials
- multiple colors
- multiple rod diameters
- triangle profiles
- private labeling
- bulk quantities
- repeat production
See Plastic Welding Rod Supplier .
Custom Welding Rod for Hot Air Plastic Welding
Custom round and profile welding rod can be used with suitable hot air plastic welding equipment.
The rod profile should be compatible with the selected nozzle and welding method.
Changing from 3mm to 5mm rod, for example, changes the amount of material that must be heated and deposited during the weld.
Custom Feedstock for Extrusion Welders
Some hand extrusion welders use thermoplastic rod or wire as their feedstock.
If a particular extrusion welder requires a specific feed diameter, custom rod manufacturing may provide a suitable solution.
Always provide the equipment manufacturer's actual feedstock specification.
See Extrusion Welding.
Custom Welding Rod Packaging
Packaging can be developed around how the customer handles, stores, sells or uses the welding rod.
Possible packaging requirements include:
- 1 kg / 2.2 lb spools
- larger production packages
- bulk packaging
- customer labels
- private-label packaging
- customer-specific product identification
New Image Plastics commonly manufactures welding rod on 1 kg / 2.2 lb spools.
Custom Plastic Extrusion
A project does not necessarily have to be conventional plastic welding rod.
New Image Plastics Manufacturing also works with custom thermoplastic extrusion and specialty profiles.
This capability can be useful when a customer needs:
- a new thermoplastic profile
- a replacement for a discontinued extrusion
- a specialty filler shape
- a custom color profile
- an OEM thermoplastic component
- new product development
Developing a New Plastic Welding Rod
Some projects involve more than changing the diameter or color. A new welding rod may need to be developed around a specific thermoplastic product or welding behavior.
Development work can involve:
- reviewing the parent material
- selecting candidate thermoplastics
- evaluating additives or color concentrates
- producing sample quantities
- testing extrusion behavior
- customer welding trials
- adjusting the formulation or profile
- moving the successful material into production
For specialized applications, testing should determine whether the finished rod actually meets the required welding and service performance.
How the Custom Welding Rod Process Works
-
Define the material.
Identify the thermoplastic being welded and, when possible, the resin grade or formulation. -
Define the dimensions.
Specify the diameter, triangle dimensions or custom profile. -
Define the color.
Provide a sample, color target or existing product when a custom color is required. -
Define the application.
Explain whether the rod will be used for hot air welding, extrusion welder feedstock, tank fabrication, flooring, repair, OEM installation or another process. -
Define the quantity.
Provide expected development quantity and eventual production volume. -
Evaluate manufacturing feasibility.
The material, profile, tolerance and packaging requirements are reviewed. -
Produce development material when required.
New materials or profiles may begin with sample or trial production. -
Test the welding rod.
The customer evaluates the rod using the actual parent material, equipment and application. -
Move to production.
Once the specification is established, repeat manufacturing can be scheduled.
What Information Should You Send for a Custom Quote?
The more information available at the beginning, the easier it is to evaluate a custom welding rod project.
| Information | Example |
|---|---|
| Material | HDPE, PP, rigid PVC, PVDF, ABS, PETG, TPU |
| Resin grade | Manufacturer and grade number if known |
| Rod size | 3mm, 4mm, 5mm or custom diameter |
| Profile | Round, triangle or custom shape |
| Color | Natural, black, red or custom color match |
| Quantity | Pounds, kilograms or number of spools |
| Packaging | 1 kg spool, bulk or custom packaging |
| Application | Hot air welding, tank fabrication, extrusion welder, OEM repair |
| Reference | Existing rod sample, sheet sample or dimensional drawing |
Can an Existing Welding Rod Be Duplicated?
If a welding rod is obsolete, imported, difficult to obtain or made specifically for another manufacturer, a sample can be evaluated to determine whether a comparable profile and material can be developed.
Useful information includes:
- physical rod sample
- material identification
- resin specification if available
- profile drawing
- color requirement
- parent plastic sample
- intended welding process
Why Work Directly With a Welding Rod Manufacturer?
Custom projects often require communication that is difficult when buying through multiple layers of distribution.
Working directly with the manufacturer makes it easier to discuss:
- material selection
- resin grade
- dimensional tolerances
- color matching
- profile development
- sample runs
- packaging
- production quantities
- private labeling
- new product development
Frequently Asked Questions
Can you make custom plastic welding rod?
Yes. New Image Plastics Manufacturing can evaluate custom materials, diameters, profiles, colors and packaging requirements.
Can you match the color of my plastic sheet?
Custom color matching can be developed from suitable samples or color requirements while using the appropriate thermoplastic base material.
Can you make custom HDPE welding rod?
Yes. Custom HDPE welding rod can include special colors, diameters, profiles, resin requirements and packaging.
Can you make custom polypropylene welding rod?
Yes. PP welding rod can be manufactured to customer requirements, subject to material and production feasibility.
Can you make custom PVC welding rod?
Rigid and flexible PVC welding rod requirements can be evaluated. The actual PVC formulation should be identified whenever possible.
Can you duplicate my triangle welding rod?
A physical sample and dimensional drawing can be evaluated to develop a matching or comparable extrusion profile.
Can you make a diameter other than 3mm, 4mm or 5mm?
Yes. Nonstandard diameters can be evaluated as custom extrusion projects.
Can I supply my own plastic compound?
Customer-specified or customer-supplied thermoplastic compounds can be evaluated for extrusion feasibility.
Can you manufacture private-label welding rod?
Yes. Private-label and OEM programs can include customer-specific materials, sizes, colors, packaging and labeling.
Can you make a small trial before production?
New or specialized projects can be evaluated for development or sample production before moving into larger production quantities. The appropriate trial size depends on the material and project.
Do you manufacture welding rod in the USA?
Yes. New Image Plastics Manufacturing produces thermoplastic welding rod in Ohio, USA.
Related Plastic Welding Rod Resources
- Plastic Welding Rod
- Plastic Welding Rod Manufacturer
- Plastic Welding Rod Supplier
- Plastic Welding Rod Sizes
- HDPE Welding Rod
- Polyethylene Welding Rod
- Polypropylene Welding Rod
- PVC Welding Rod
- PVDF Welding Rod
- ABS Welding Rod
- PETG Welding Rod
- TPU Welding Rod
- Plastic Welding Guide
- Hot Air Plastic Welding
- Extrusion Welding
- Plastic Welding Tools
- Plastic Welding Troubleshooting
- Thermoplastic Welding
- Plastic Fabrication
Need a Custom Plastic Welding Rod?
New Image Plastics Manufacturing can evaluate custom welding rod requirements for thermoplastic fabricators, distributors, OEMs and equipment manufacturers.
Send the material, size, profile, color, quantity and application. If you are trying to duplicate an existing welding rod, a physical sample or dimensional drawing can also be helpful.
Materials: LLDPE, LDPE, MDPE, HDPE, HMWPE, polypropylene, rigid PVC, flexible PVC, PVDF, PETG, ABS, TPU and other thermoplastics.
New Image Plastics Manufacturing
Canal Fulton, Ohio, USA
Phone:
330-854-3010
Email:
newimageplastics@sbcglobal.net