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What are the practical applications for ultrasonic welding?

What are the practical applications for ultrasonic welding?

Ultrasonic welding means joining without adhesives, screws or heat from an outside source. During this process, plastics are strategically melted by means of ultrasonic vibrations so that a cohesive or form-fit joint is produced. As economic production method with short cycle times, ultrasonic welding ensures a large degree of process control and repeatable quality results.

Industrial Uses:

Automotive industry applications:

A car is composed of far more than 10,000 individual parts, many of which are made of thermoplastic materials. Ultrasonic welding qualifies as the best suitable joining technology for scenarios with large production numbers of components:

* High-strength and fast

* Dimensionally accurate

* Impeccable visual appearance
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Packaging industry applications:

Food is better protected by good packaging and kept fresh longer which is more sustainable. Ultrasonic sealing technology has become an established and economic alternative of heat sealing.

* Absolutely tight seals

* High output

* Monitoring of seal quality

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Hygiene industry applications:

Laminating without the use of adhesives and embossing without the use of heat? The absolutely clean ultrasonic technology for nonwovens makes this possible. Materials are joined by means of locally limited heat generation

* Skin-friendly

* Fast

* Soft and yet stable

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Ultrasonic welding ensures maintained functionality of the components and provides continuous process monitoring unrivaled by other processes. Up to 130 different process reference data are available and can be visualized:

* Stable weld process

* Validated

* Repeatable

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Electronic industry applications:
Sensors and electrical components are not only used in industrial manufacturing but also in automation engineering or in daily use. Ultrasonic welding is particularly suitable for their production and complies with product requirements, such as:

* High strength

* Reliable functionality of components

* 100% tightness

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Consumer industry applications:
Using ultrasonics, consumer components can be produced and joined in a cost-effective way; at the same time, the process provides great flexibility in terms of design. High requirements for visual appearance, production speed, or geometry are met.

* Light-weight and robust

* 100% tightness

* Mark-free surfaces


Other Applications for Ultrasonic Welding

INSERTING
Threaded inserts, grub screws or other parts can be ultrasonically embedded in thermoplastics.
 


STAKING
Melting and forming of a plastic stud to retain or lock another material, often dissimilar, in place.

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SPOT WELDING
Used for joining two thermoplastic parts with no pre-formed hole or energy director. This technique is particularly suited to large parts or parts with complicated geometry and thermoformed or blow-molded parts without a joint.

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SWAGING
Used to capture another component of an assembly by melting and reforming a ridge of plastic around the component. The ridge locks the second component in place without welding the materials together.

 

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