The use of intrinsically conductive polymers in welding of plastics and composites offers the possibility of developing new welding methods. Intrinsically conductive polyaniline (PANI) composite gaskets were used to microwave weld high density polyethylene (HDPE) bars. Two composite gaskets were made from a mixture of HDPE and PANI powders in different proportions. Adiabatic heating experiments were used to estimate the internal heat generation and electric field strength in the gasket. During welding, the effects of heating time, heating pressure and welding pressure were evaluated. It was found that increasing the heating time and the welding pressure Increased the joint strength. The maximum tensile joint strength was achieved using a 60 wt% PANI gasket with a heating time of 60 sec and a welding pressure of 0.9 MPa; this resulted in a tensile weld strength of 24.79 +/- 0.34 MPa, which equals the tensile strength of the bulk HDPE.