heatfused

Heatfused is an adjective used to describe a bond or material created by applying heat to adjacent surfaces so they melt or soften and then merge together. The process relies on heating to at least the melting or softening point of the involved materials, often combined with pressure, to promote diffusion and coalescence at the interface. When performed under appropriate conditions, heatfused joints tend to be continuous and (ideally) indistinguishable from the surrounding material.

Applications and methods vary by material. In plastics, heatfusing is common for joining thermoplastics through methods such as hot plate welding, infrared heating, or friction-based processes that generate the necessary heat at the seam. In textiles, heatfused bonding is used with fusible interlinings or heat-activated adhesives to attach fabrics without sewing. In glass and ceramics, heat fusion can be used in laminates or frit-based joins, where surface layers are melted to form a bonded structure.

Materials and conditions matter. Thermoplastics are especially suited to heatfusing because they re-melt and flow under heat. Other materials may require specialized temperatures, surface preparation, or coupling agents to achieve a reliable bond. Benefits of heatfused bonds include cleanliness, uniform appearance, and strong interfacial strength when properly executed, but limitations include the need for material compatibility, potential thermal distortion, and energy requirements.

See also: welding, soldering, diffusion bonding, lamination.