Ultrasonic welding, our new technique
For some time we have been investigating the possibility of applying ultrasonic welding as a joining technique. Meanwhile we have purchased an ultrasonic welding machine of the brand Branson. Due to the high power of this machine we are able to weld a wide range of products. When applying this method, we were amazed by the speed of the welding process and the strength of the welded joint. In addition, it turns out to be quite possible to weld products with high-quality sight surfaces. In this blog, we discuss the main advantages of this technique for plastic applications.
Also read our 2 other blogs on ultrasonic welding: Ultrasonic Welding, How It Works and Ultrasonic Welding: Types and Applications.
How it works
Ultrasonic welding is an advanced technique used to join thermoplastics efficiently and reliably. This method uses high-frequency vibrations to generate heat, which melts the plastic on the weld and creates a solid joint. It is important, however, that the welded joint is specially designed for this purpose.
Fast and efficient processing
One of the most notable advantages of ultrasonic welding is the speed of the process. The ultrasonic welding itself typically occurs within one second, allowing for high production rates. Virtually no heat is released during ultrasonic welding, allowing the product to be grasped immediately after ultrasonic welding. In addition, there is no need for curing time, as with adhesives, which further reduces lead time. Placing the product in the take-up mold also typically requires very little time.
High connection quality
Ultrasonic welding produces strong and durable joints without the use of additives such as adhesives or mechanical fasteners. This results in a clean, tight weld without visible marks, which is especially important for aesthetic or hygienic applications. The strength and quality of the weld are determined by the design of the weld joint on the parts being ultrasonically welded.
Cost savings
Because no additional materials such as glue are required and the ultrasonic welding process is easily automated, production costs can be significantly reduced. The high processing speed also contributes to a more efficient production process and lower labor costs. However, specific tools such as a recording jig and sonotrode are required for each product. These are custom made to suit the product to be welded. These recording jig and sonotrode usually last a very long time.
Environmentally friendly
Since no solvents or other chemicals are used, ultrasonic welding is an environmentally friendly joining method. Especially since energy consumption is low. No harmful fumes are released, contributing to a safe and clean working environment.
Versatility in applications
This type of welding process is suitable for a wide range of thermoplastic materialsand is used in various industries such as automotive, medical devices and consumer electronics. The process is ideal for both small and medium-sized plastic parts and offers flexibility in design and production.
Conclusion
Ultrasonic welding offers numerous advantages for joining plastic parts. The combination of speed, high joint quality, cost savings, environmental friendliness and versatility makes it an attractive choice for modern manufacturing processes.
