Innovative Hot Bar Soldering for the efficient soldering process of our connection technology

We would like to present you with a suitable technology for the efficient soldering process of our connection technology. Therefore we have developed and implemented a very interesting solution. The Hot Bar Soldering process connects different connection parts with each other.

Due to the fact that the contact pads are often soldered to a PCB it is important that the materials used offer a slightly different alloy, in which reliable solder points can be created. Before the soldering process one of the two solder points is coated with flux and then the connector part is pressed onto this point by the still cold thermode.

Subsequently a brief heating of the thermode is performed until the melting temperature is reached. The system is cooled down very fast after the soldering has taken place. Air is almost always used for the cooling.

Bügellöttechnik Übersichtsblatt
Neuschaefer Elektronik Bügellöttechnik

Installation of the Hot Bar Soldering System

Although Hot Bar Soldering is a single solder process multiple solder connections are almost always produced. Another great advantage is the mechanical fixation of the solderable part by the thermode before the soldering process starts. As a result both parts can perfectly be applied to the appropriate position.

Previous Hot Bar Soldering technique

Currents between 150 and 300 Ampere are used to heat the thermode. In classical systems the current is generated by a transformer. Due to thick supply cables (thumb's width) leading the current to the thermode these systems are nearly immobilized. They only move a few millimeters in the direction of the stroke which is sufficient to cause cable breaks - especially at the thermode connection – in a 24/7 operation.

Lossfree Energyapplication with Hot Bar Smoldering

Our Hot Bar Soldering technique

We also use currents up to 300 Ampere in the thermode, but in our approach the thermode is placed directly behind the power electronics which converts the input current of circa 15 Ampere (input voltage 24V) up to 300 Ampere. The 24 Volt supply line is thin in comparison to the supply lines of conventional systems. Additionally the whole system is packed in an aesthetic designer housing.



During the soldering of connections Aluminum core PCBs behave as in the future application: They dissipate heat very well which makes it hard to connect a part with these PCBs by soldering. The ideal solution for this problem is a Hot Bar soldering system since it applies enough energy to the solder points in order to produce a reliable connection within a short time.  Interesting applications

We also offer the suitable connecting elements to maintain sufficient high current flow.

Practical Example:
One application is the production of a daytime running light with high power LEDs mounted onto an Aluminum core PCB and connected to one another. In this case the connection technology consists of THT-jumpers with Hot Bar Soldering pads. The soldering was done by Hot Bar Soldering process:

IMS Board


We present the heart of our system, the Hot Bar Soldering Generator BLG-300. Its design is unique and it is only exceeded by its function.

Technical Data:
Power supply: 24 Volt DC not stabilized
Maximal current: 15 Ampere
Temperature of the thermode: PT-100 measurement
Output: ???
Temperature range: ???
Air pressure: 6 bar needed (oil- and water free)
Connection: Sub-D (connection diagram see below)
Time of Soldering Cycles: Ca. 6 to 8 seconds

Gewinner German Design Award 2014

Setup of the thermode

Usually the thermodes are made of stainless steel, but also other materials, e.g. Wolfram is possible We deliver a broad range of different widths and we often adapt the thermodes individually to the customers soldering requirements. Due to a special thermode profile we achieve an extremely homogeneous heating.

Integrated in the thermode there is a temperature sensor positioned in a way to produce as close as possible measurement results. Due to the complete pluggable connections the change of the thermode is so simple that you need about 1 minute. For series production we recommend buying two Hot Bar Soldering Generators to change the thermode without time-related stress and or production interruption.

Working cycle

Due to our special generator technique leading to a higher power of the Soldering Bar at the thermode and the compatible control electronics we provide a fast, high-performance system. Subsequently we chart a working cycle diagram as it is used to solder flex strips to a PCB. Depending on the application the cycle times can vary in time.

By performing in house experiments and continuous parameter adjustment the optimal cycle times are achieved. In many cases our systems work in three eight-hour shifts where a split second is crucial. Thereby, it is important to choose the cool down time – the time for cooling the solder bar before it is lifted up from the soldering point.

Standard Thermode

Tabletop system BLS-50

Our Hot Bar Soldering system BLS-50 is a complete system for direct use in the ongoing production. The Hot Bar Soldering station is based on a universal mounting in the base plate where various equipment can be applied. We can also construct and produce the suitable mounting setup. In its simplest form you send us the parts which are to be soldered and we construct the compatible mounting plate for you.

With the included control electronics all required parameters can be set. The apparatus is controlled with a two-button operation and the whole device corresponds to the current CE safety standard. To implement the Soldering system a 380 Volt (16A) power supply and compressed air (6-8 bar) is required. The system consists of the tabletop and the associated power supply:

Upon request the Hot Bar Soldering station BLS-50 (model BLS-50-D)is available which allows the pressure to be monitored electrically. In this case, a precise control unit for compliance with the prescribed target pressure values is provided. This special function is important for all processes where materials are soldered to very sensitive substrates as well as monitoring and documenting all production parameters permanently. The control electronics which are included enables the setting of the following parameters:

Production line

In our affiliated company, NE-Sensoric GmbH & Co. KG, we build production lines matching perfectly to our Hot Bar Soldering system. Again, the focus is always on a universal possible application. The modular construction shortens the production and delivery time. By the use of industrial robots the Hot Bar Soldering system is able to solve nearly every soldering task.

Soldering in angular positions, offset rows as well as different positions are no problem for our system. If you want to change the thermode we recommend that you replace the complete solder head since time required is less than a minute. Such a system allows the customization to every new production situation in your company.

Soldering Temperature
Industrial Robot with Soldering
Automatic Hot Bar Soldering System