Polymer Stir Welding (PSW) replaces adhesive bonding with a fully automated, solvent‑free welding process that is up to seven times stronger than glue and supports true material‑mix joints. The method welds plastics to metals, wood, cast alloys, and reinforced polymers while remaining recyclable, contamination‑free, and ageing‑resistant. It eliminates pre‑ and post‑processing, reduces OPEX by up to 50%, and installs on existing machines within minutes. PSW delivers industrial‑grade performance—e.g., ~18 MPa tensile shear strength in PC‑steel joints and near‑virgin properties in PA66 GF30—and provides a scalable, automation‑ready joining standard for lightweight hybrid composites in automotive, mobility, and circular‑economy applications.
