Ultrasonic Welding of Plastics: Process, Benefits, and Applications

Ultrasonic welding services include ultrasonic welding plastic which provides several advantages over traditional production methods of securing plastic pieces together. The process involves using thermoplastic materials and forming or joining them together using ultrasonic energy into heat energy to melt the plastic and create a bond between the plastic materials.

How Ultrasonic Welding Works

There are six general steps one must understand to know how ultrasonic welding works. The overall process is not complex, but it does require the right ultrasonic welding equipment.

Step 1:  The plastic parts are placed into the ultrasonic welding machine. One part is placed on the bottom and the other on top of the first one.

Step 2: The ultrasonic horn is lowered onto the plastic part on top. The horn is made from aluminum or titanium.

Step 3: The parts are “clamped” together using some type of applied force to secure the plastic parts in place.

Step 4: The ultrasonic horn is activated to generate ultrasonic wavelengths at ranges from 20 to 40 kilohertz (kHz) per second to weld the pieces together. As the wavelengths pass through the plastic parts at the joint, it is transformed into heat energy due to friction.

The welding process continues until the plastic reaches its melting point and the two pieces are welded together. The machine then stops the welding process and the plastic starts to cool.

Step 5: The parts continue to cool but are held clamped together for a predetermined hold time. Sometimes additional force is applied at this step for better joint strength.

Step 6: The ultrasonic horn is raised, and the parts are removed from the machine. The two plastic parts are now welded together and have become a single part.

Why Use Ultrasonic Welding?

The process might seem like it takes a long time. Yet, for most types of plastic parts and components, the overall process from start to finish occurs within seconds. Plus, ultrasonic welding is not limited to plastics. It can also be used to weld together various metal parts and components like copper, aluminum, or the contacts on circuit boards.

Not to mention, ultrasonic welding is much safer than conventional welding processes. There are no gases, fumes, bright UV light, and other concerns that can pose safety risks.

Best of all, the welds created using ultrasonic energy are just as durable and strong as welds created using conventional methods. The same results can be achieved using less energy, lower temperatures, and less time.

What Industries Use Ultrasonic Welding?

The use of ultrasonic welding can be found in many industries. Some of the top industries that use this welding process frequently include:

• Packaging:Hermetically sealed plastic packages, as well as beverage, frozen and fresh food, and candy bar containers and packages are some products sealed using ultrasonic welding.

• Automotive: The “keyless” key fobs and many of the aluminum parts found on modern automobiles are made using ultrasonic welding.
• Aerospace: Aluminum and plastic parts and components are two lightweight materials used in the aerospace industry made using ultrasonic welding.
• Electrical: Parts and components made using ultrasonic welding are wire harnesses, electrical motors, capacitors, transformers, and more.
• Computer: From circuit boards to attaching chips to microcircuits, ultrasonic welding can be used for many production tasks.
• Medical: There are several different types of medical devices on the market today that were assembled using ultrasonic welding—like medical sensors in pacemakers.

Ultrasonic welding is beneficial in many industries and products. To learn more about ultrasonic plastic welding services and ultrasonic metal welding services, please feel free to contact Laszeray Technology, LLC at 440-582-8430 today. We offer a wide range of custom manufacturing and secondary and finishing operations services, including rapid prototyping, design, and engineering solutions.