Welding instead of glueing.
Efficient. Clean.
Scalable.

The right PSW solution for your application — from standard polymers to advanced multi-material structures.

Applications:

Automotive

Aviation & Aerospace

Furniture & Yacht Building

Electronics & White Goods

The Current Challenge

Multi-material bonding is today’s bottleneck.

Glueing is slow, harmful to the environment, and difficult to reproduce. Screws and rivets weaken the components. Traditional welding does not work at all for many material combinations, especially when polymers meet metals, composites, or high-performance polymers.

  • Long curing times block cycle times
  • Adhesives & solvents harm humans and the environment
  • Mechanical fasteners increase weight and costs
  • Adhesive layers severely hinder recycling

The Solution

PSW — Polymer Stir Welding for Multi-Material Joining.

PSW joins a wide variety of materials in a single, one-step process — without adhesives, without curing time, and without additional fasteners. The result: ultra-high-strength bonds directly on standard CNC machines.

High-strength

Instantly load-bearing

Adhesive-free &
recyclable

Plug-and-play

Two Systems — One Technology

PSW Core & PSW Flex

Both tools are based on the same core PSW technology and can be deployed directly into standard CNC machining centers as plug-and-play HSK or SK interface. They differ primarily in their application focus.

PSW Core

Standard Polymers

PSW Core

Cost-effective. Robust. Production-ready.

THE CLEAN REPLACEMENT FOR BONDING!

Reproducible joining of standard polymers and wood-polymer composites — as a clean, single-step replacement for adhesive processes.

INDUSTRIAL APPLICATIONS:

  • Furniture & Interiors (Wood-Polymer Composites / WPC)
  • Technical Assemblies & Enclosures
  • Packaging made of standard polymers
  • Prototyping & low-to-medium volume series production
PSW Flex

Multi-Material & High-Performance

PSW Flex

Flexible. High-strength. Multi-material.

REDEFINING THE BOUNDARIES OF WELDING!

Joints where conventional processes fail: polymer-to-metal, fiber-reinforced materials, and high-performance polymers like PEEK — everything Core can do, plus high-performance capabilities.

HIGH-PERFORMANCE TARGET INDUSTRIES:

  • Automotive hybrid modules & structural components
  • Aerospace: composite lightweight structures
  • Polymer-to-metal joints (Aluminum, Steel)
  • PEEK, organic sheets (Organo-sheets), fiber-reinforced polymers
  • Medium-to-high volume series production

Material not listed?

We conduct feasibility studies — tailored specifically to your exact material combination.

Every application is unique. Many clients need to join materials that are not listed in our standard portfolio. This is precisely why we offer customized feasibility studies: We test your specific material combination, document the achievable strengths, and provide a reliable foundation for your decision — before you invest.

Why PSW

A technology setting
new benchmarks.

7x

Higher Strength

Compared to adhesive bonds

0s

Curing Time

Instantly load-bearing after joining.

1-Step

Single-Stage Process

Fully automatable

100%

Adhesive-free

Clean separation & recycling

Direct Comparison

Core vs. Flex in detail.

All key features at a glance — helping you find the right system for your requirements.

Specification

PSW Core

PSW Flex

Polymer-to-Polymer

Polymer-to-Wood

Polymer-to-Metal

Fiber-Reinforced Polymers

High-Performance Polymers (PEEK)

Process Temperature

up to 280 °C

up to 400 °C

Interface

HSK / SK

HSK / SK

Recommended for

Series / Standard

Multi-Material & High-Perf.

Solution Finder

Which tool is right for your application?

A single question is usually all it takes to make the right choice:

Your Application

Polymer + Polymer or Wood?

Cost-effective series production of standard polymers

Furniture

Enclosures

Packaging

Your Application

Polymer + Metal, PEEK or Composites?

High-performance joints with multi-material capability

Automotive

Aerospace

Hybrid Components

Fields of Application

Where can PSW be used?

Automotive

Battery trays, structural components, hybrid modules

Aviation & Aerospace

High-performance lightweight design, composite joints

Furniture & Yacht Building

Wood-polymer systems in series production

Electronics & White Goods

Hermetic, heavy-duty polymer joints

Testimonial

„We see great potential in the solution developed by royos to enable new concepts and successfully bring them into series production.”

— EDAG Group · Dr.-Ing. Stefan Caba

FAQ

Frequently Asked Questions

What are the system requirements for PSW?

PSW tools are designed as plug-and-play HSK or SK interface and integrate directly into any standard CNC machining center. Spindle: HSK/SK, 0–5,000 RPM. Required: torque arm (or the option to attach a torque arm), compressed air at 0.6 MPa (6 bar), power supply 230 V / 50 Hz / 16 A. For machines with an enclosed workspace, either S4 operation must be supported, or a suitable feed-through for the cable package must be available (e.g., via a preparation for oil mist extraction).

Both tools are available as plug-and-play solutions for HSK and SK interfaces (Core: Weldon Ø 16 mm, Flex: Weldon Ø 20 mm) and integrate seamlessly into standard CNC machining centers.

Typical commissioning, including operator training and pre-programmed welding parameters, takes 1–3 days on-site.

Core: PC, PMMA, PA, PE, PP, POM, TPU, wood, and wood-based materials. Flex additionally supports: aluminum, steel, PEEK/PEK, organo-sheets, fiber-reinforced polymers, and high-temperature polymers. Material not listed? We offer customized feasibility studies.

Yes — we offer maintenance contracts including wear parts (pin tools, seals, hot/cold ends, high-performance heating elements, coolant) and remote support.

1–3 months, depending on the tool type and specifications.

Datasheet

Technical specifications at a glance.

Select a tool to view the full technical specifications directly.

Welding Tool

Model

Core Basic

Interface

Weldon Ø 16
(easy tool change)

Heating Element

High-performance, up to 280 °C
welding temperature

Cooling

Water-cooled main bearing & front end

Control Cart

Control System

Beckhoff 12″ touchscreen

Software

PSW software, automated
welding process

Programs

Pre-programmed
welding parameters

Cooling Unit

Cooling Capacity

1.3 kW

Cooling System

Water chiller, +5 °C to +30 °C

Function

Stable cooling cycle / process stability

Materials & Applications

Materials

PC, PMMA, PA, PE, PP, POM, TPU,
wood / wood-based materials

Joint Types

Polymer-to-Polymer,
Polymer-to-Wood

Recommended Industries

Furniture, packaging,
technical assemblies

System Requirements

Spindle

HSK / SK, 0–5,000 RPM
(others available on request)

Torque Arm

Required (or mounting
option available)

Compressed Air

0.6 MPa (6 bar)

Power Supply

230 V / 50 Hz / 16 A

Accessories

Wear Parts

Pin tools, seals, hot/cold ends, heating elements, coolant

Welding Tool

Model

Flex Basic

Interface

Weldon Ø 20
(easy tool change)

Heating Element

High-performance, up to 400 °C
welding temperature

Cooling

Water-cooled housing & front end

Control Cart

Control System

Beckhoff 12″ touchscreen

Software

PSW software, automated
welding process

Programs

Pre-programmed welding
parameters

Cooling Unit

Cooling Capacity

1.3 kW

Cooling System

Water chiller, +5 °C to +30 °C

Function

Stable cooling cycle / process stability

Materials & Applications

Materials

All Core materials + aluminum, steel, PEEK/PEK, organo-sheets, fiber-reinforced polymers, high-temperature polymers

Joint Types

Polymer-to-Metal,
Multi-Material, Composites

Recommended Industries

Automotive, aerospace, hybrid components

System Requirements

Spindle

HSK / SK, 0–5,000 RPM
(others available on request)

Torque Arm

Required (or mounting
option available)

Compressed Air

0.6 MPa (6 bar)

Power Supply

230 V / 50 Hz / 16 A

Accessories

Wear Parts

Pin tools, seals, hot/cold ends, heating elements, coolant

Optional Accessories

Expand your system.

Add-ons to tailor your PSW system to specific components, higher speeds, or unique requirements – available for both Core and Flex.

Speed Optimization

Custom hot-end design for enhanced cooling performance and shorter cycle times.

Custom Configurations

Precise alignment of the cooling geometry to your exact component and process.

Filler Extruder

Expands the PSW process with targeted material feed, functional additives, and custom finishing options.

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Product Inquiry

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