Purpose-built handheld BPR configuration
The Novaseal® GT-100 was engineered from the beginning as a handheld wedge welder. It combines the simplest complete BPR configuration with operator-focused ergonomics, enclosed construction, dependable temperature control, and broad production capability.
“Handheld” describes the GT-100 form factor. It does not limit the machine to occasional repair work. In suitable applications, the GT-100 may be the principal production welder because the operator can bring the wedge-and-pressure arrangement directly to the seam.
The GT-100 is purpose-built for handheld operation rather than adapted from a compact motorized or automated wedge-welding mechanism. Its simplicity is the result of deliberate engineering intended to improve operator comfort, reliability, protection, and long-term performance.
Operator-focused engineering
The GT-100 is not a compact automated wedge welder carried by hand. Its housing, handle, wedge, guarding, cooling, and controls were developed as one handheld system.
The handle geometry supports a comfortable natural grip for extended use. The overall housing shape also helps prevent the machine from rolling into a position where the heated wedge can contact and burn the material.
An internal thermodynamic cooling system allows the electronics to remain enclosed, helping prevent dirt, dust, and foreign debris from entering the control area.
The wedge geometry supports left- or right-hand use. Heat guards are positioned to help protect the operator’s hand across a wide range of welding positions.
Ni-200 nickel provides corrosion resistance, thermal durability, and resistance to carbon flaking that can contribute to cold spots in other wedge constructions.
PID temperature control with K-type thermocouple feedback supports accurate regulation across demanding heat requirements.
The welding motion requires no powered drive train, gears, belts, chains, or motorized feed rollers. The operator supplies travel and pressure directly.
Industrial production
The GT-100 can be used wherever manual guidance provides an effective way to control the seam path, material overlap, wedge position, and applied pressure.
Its compact configuration is particularly relevant when the product is difficult to move through a conventional wedge welder or when the seam is located within an assembly, along an edge, or in an area inaccessible to larger continuous equipment.
Production suitability depends on the material, seam geometry, operator access, required rate, and acceptance criteria.
BPR architecture
The GT-100 combines the required BPR components in one operator-guided device. The wedge heats the intended joining surfaces, and the base pressure roller arrangement supports and compresses the material immediately behind the wedge.
The heated wedge transfers thermal energy directly to the overlapping thermoplastic surfaces. Wedge temperature and travel speed must be matched to the complete material construction.
The BPR configuration applies pressure against a supporting base or surface rather than requiring the material to pass between the opposing rollers used in conventional wedge-welding machinery.
The operator moves and guides the complete device along the seam. The product can remain substantially supported while the machine follows the required path.
Purposeful simplicity
The GT-100 welding system has no powered moving mechanical components, drive train, gears, belts, chains, or motorized feed rollers. The operator supplies the travel while the heated wedge and hand-applied pressure produce the seam.
This eliminates routine drive-train maintenance and the mechanical feed problems associated with powered welding motion. The GT-100 requires no routine mechanical maintenance associated with producing the weld.
Wedge material and directionality
BPR systems typically use a larger Ni-200 nickel wedge. The wedge offers excellent thermal conductivity, is omnidirectional, and is mechanically stronger and more durable than the smaller silver wedges typically used in conventional equipment. Its corrosion and wear resistance can provide exceptionally long service life.
Ni-200 provides the thermal conductivity required to transfer heat from the controlled wedge into the intended material surfaces. It also offers excellent corrosion resistance and high durability under repeated production use.
Unlike the smaller directional silver wedges typically used in conventional opposing-roller equipment, the larger BPR wedge can be used in either direction.
Silver wedges may require replacement under heavy use. Based on Nova Products Mfg., Inc. operating experience, the larger Ni-200 wedge may last for the useful life of the equipment when it is not damaged or misused.
Application range
The GT-100 is most valuable when its compact size and manual control solve a production or access problem. The machine should be selected because its geometry fits the application—not simply because the seam is short or requires repair.
The GT-100 may serve as the main production machine for repetitive products and seam paths suited to operator-guided BPR welding.
The handheld BPR form can be used for roofing products and membrane applications where the wedge must be brought to the supported overlap.
BPR handheld equipment can reach areas and seam sections that may not be practical for conventional opposing-roller machines.
Operating examples
The handheld BPR form can reach patch areas, completion seams, edges, and other locations where the wedge must be brought directly to the supported work.
Materials and settings
Successful GT-100 welding depends on the complete material composition and layer structure, including film or coating chemistry, reinforcement, thickness, surface treatment, printing, overlap, and required seam performance.
Wedge temperature, travel speed, applied pressure, support, and operator technique must work together. Polymer name alone does not establish production suitability.
The GT-100 can weld different material thicknesses and weights without modification to the basic machine configuration. It can also seal dissimilar materials when the actual contacting thermoplastic surfaces are compatible. Temperature, speed, pressure, support, and technique are adjusted to the construction.
Relationship to other BPR systems
The GT-100 is the purpose-built handheld implementation of the BPR method. Integrated systems configure the wedge, pressure support, material handling, movement, and controls directly around a specific application.
The operator guides a complete handheld BPR wedge welder along the seam.
The GT-200 is engineered specifically for compatible nonwoven textile materials. Wheel-mounted walk-behind equipment is one GT-200 implementation rather than the definition of the system.
Integrated systems for HDPE geomembranes, vinyls, and other heavier heat-weldable plastics may incorporate laser guidance, split-wedge pressure-verification channels, custom material handling, controls, and tooling.
Manufacturing and delivery
Novaseal® GT-100 BPR Handheld Wedge Welders are manufactured with limited inventory. Typical delivery is approximately two to four weeks, subject to current availability and production scheduling.
Manuals, parts, service, application evaluation, and technical support are provided by Nova Products Mfg., Inc.
Buyer questions
No. It is frequently used for production work. Repair and patchwork are additional uses.
The omnidirectional Ni-200 BPR wedge permits operation in either travel direction when the material and application arrangement allow it.
Limited inventory is maintained, but typical delivery is approximately two to four weeks and depends on current availability and production scheduling.
The GT-100 welding system has no powered moving mechanical components, drive train, gears, belts, or motorized feed rollers. It requires no routine mechanical maintenance associated with the welding motion.
Yes, when the actual thermoplastic joining surfaces are compatible. Different material weights and thicknesses can be welded without modifying the basic machine configuration; process settings are adjusted to the construction.
Novaseal® GT-100
Nova Products Mfg., Inc. manufactures and supports the Novaseal® GT-100 and evaluates materials, seam requirements, production uses, roofing applications, repair work, and custom BPR development.