Ultrasonic welding is renowned for its speed, cleanliness, efficiency, and repeatability
The mentioned process involves high-frequency vibration (ranging from 20 to 40 kilohertz) that melts the material at the juncture of the plastic parts. Both amorphous (e.g., polystyrene) and semi-crystalline (e.g., nylon) thermoplastics are suitable for ultrasonic welding. Ideally, both parts in a weld are made from the same material for optimal results. However, many combinations of unlike plastics can be ultrasonically welded if their melting temperatures are similar.
Ultrasonic weld fixtures play a crucial role in achieving consistently high-quality welds. Their design must carefully consider various factors, including:
- Size and shape of the parts being welded
- Weld pressure and energy levels
- Cosmetic requirements for aesthetics
- Material compatibility
- Tolerances for precise alignment
- Assembly requirements, such as hermetic seals or structural joints
- Flashing requirements for excess material removal
High structural joint
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