High-Frequency Welding
One press melts and cuts at the same time. That is how the foam sticker in your hand is made. We are in Shenzhen, close to Dongguan — bring your own foam or artwork, contract processing accepted.
What actually happens
The printed foam goes between the upper and lower tools. A high-frequency field makes the molecules inside the material rub at high speed and melt from within; in the very same stroke the edge is cut through. Lift it, tear off the scrap, and you have a finished sticker.
A high-frequency field makes the material's molecules rub against each other and melt from within. No glue, no external oven.
Melting and cutting happen in the same stroke — one less step, one less chance of misalignment.
The cut edge is heat-sealed: no fraying, no delamination, no sharp edge. Exactly what children's products require.
vs. plain die cutting
| High-frequency welding | Plain die cutting | |
|---|---|---|
| Edge quality | Heat-sealed, no fraying | Cut only, frays & delaminates |
| Touch | Rounded, not sharp | Relatively sharp |
| 3D effect | Raised contour possible | Flat |
| Steps | One press | Two separate steps |
| For children's products | Better suited | Needs extra finishing |
How many per sheet
2, 4 and 8 are the most common.
Large artwork per piece
Most common balance of size & count
Many small characters in one set
Contract HF welding: what we take on
We are a foam sticker HF-welding factory in Guangming, Shenzhen — about one hour from Dongguan. Three ways to work with us, MOQ depends on your case.
Buy our foam rolls, print yourself, send it back — we make the mold and weld. Flexible quantity for packers and printers.
Finished sticker OEM: send artwork, size and quantity — foam, printing, mold, welding and packing all in one. MOQ 2,000 pcs.
Local Shenzhen / Dongguan clients get faster sampling and rush orders. Drop materials today, trial sheet tomorrow is possible.
Not every foam can be welded
This is the important part, and where we differ: we make the foam ourselves, so we know from the formulation stage which grades run on our machines and how to set them. Material-only suppliers don't run the process; sticker-only factories don't control the formula.
Polar material, welds well — our most used
Soft and puffy, ideal for kids' stickers
Non-polar — hard to weld, needs another process
HF welding does more than foam stickers
HF welding heats polar materials like PVC, TPU and EVA so they fuse themselves. If the material has enough PVC content, it can run on our machines — welding, cutting, embossing and foil stamping on the same press. All of the below are accepted; for a new material, send a sample, we test it and only then schedule production.
Printed, then HF-sealed: waterproof, abrasion-resistant, edges stay flat. A staple of kindergarten supply orders.
A foil attachment presses gold or silver foil in the same stroke — great for gift boxes and seal stickers.
Raised letters, logos and patterns on leather-like, fabric and plastic surfaces.
PVC tags welded and cut in one stroke, sealed edges — a regular in export orders.
Pencil cases, card sleeves, blister sealing — same presses, same line.
Unsure if your material will run? Send a sample — we press it and show you the result.
From roll to finished sticker, under one roof
We make the foam, arrange the mold, and run the welding ourselves — one line, one point of contact. No shuttling between vendors, tighter lead times.
Our own formula, tuned to run on our machines from day one
Send artwork, or bring your own printed sheets
Mold arranged per your drawing; tooling fee quoted, ownership is yours
One press welds and cuts
Scrap removed, inspected piece by piece
How our machines actually work
A one-man workshop can run a single press, but volume orders are won on machine configuration and scheduling. We pair flexible single-head presses for sampling with parallel dual-station production lines for bulk runs.
Two feed stations, left and right: operator A loads on one side, the press welds automatically, operator B unloads on the other side — alternating so the machine rarely sits idle. Industrial 27.12MHz HF, 5–12KW. Two operators per press, throughput nearly doubles vs single-station. This is our bulk-run workhorse.
One operator, one press, one button. Tool changes and setup are fast — new artwork is trialed here first, then parameters carry over to the dual-station production line. Small runs stay on this press too.
A high-sensitivity spark suppressor cuts the HF field the instant a spark starts, protecting the mold and material; overload auto-shutdown protects the oscillator tube. Molds are your asset — we guard them like our own.
- PLC touchscreen control: weld time, pressure and current are saved as presets — no reliance on an operator's "feel"
- Dual stations alternate loading, so the press rarely sits idle — per-press output nearly doubles
- Built-in counting — every order ships exactly to quantity, no over-runs
- Two shifts keep the line running on big orders — that is how we hold 5-15 day lead times
The press is only half the story: after weeding, every sticker is checked for sealed edges, aligned artwork and even thickness. Rejects are re-pressed or scrapped on the spot — never packed. It is the most overlooked step in volume orders, and the one that protects your brand.
FAQ
Is there a MOQ for HF welding?
Finished sticker OEM starts at 2,000 pcs. If you buy the foam, print it yourself and only bring it back for welding, the quantity is negotiable.
How many stickers per sheet?
2, 4 and 8 per sheet are the most common. We also do 1, 6, 10 or 12 — it depends on your layout and artwork size.
Can my own foam run on your machines?
Not always. Polar materials like PVC and EVA weld fine; PE and PP are difficult and need a different process. Send us a sample and we will test it on the machine.
How is tooling charged? Who owns the mold?
You provide the drawing, we arrange the mold with a specialized toolmaker. The tooling fee is quoted by artwork complexity and sheet layout, charged once. The mold is your property — we store it and run it for your orders only. Reorders within the tool's normal service life carry no new tooling fee.
My artwork is licensed IP. Will it leak?
No. We produce to your order quantity only — no over-runs. We never sell any client's licensed designs. Your mold runs for your orders only. We ask written permission before showing your product on our site or in print; without it, we show nothing or only masked samples. NDA available on request.
How big is your capacity? Will my order get bumped?
We schedule by order: dedicated sampling presses plus dual-station production lines. Each dual-station press runs with two operators alternating load/unload, and the machine is rarely idle. Multiple presses run in parallel on two shifts, so daily output reaches several thousand sheets. For production orders, the lead time goes on your confirmation and machine time is locked. Tight deadline? Tell us upfront — we keep the queue fair, no jumping, no skipping.
How long does sampling take?
Send us the artwork, size, quantity and sheet layout. We confirm the process and give you a firm timeline. Typical lead time is 5-15 days.
- Produce to order quantity only — no over-runs
- Never sell any client's licensed designs
- Your mold runs for your orders only
- Written permission before any showcase
- NDA available on request
Send artwork — we will press a trial sheet
Tell us size, quantity and stickers per sheet — quote within 24h.
Get a quote