Ultrasonic Welding

It is an ideal bonding technique for medical devices, as it utilizes the device’s own material to form a secure connection without the need for adhesives or glues.

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Ultrasonic welding
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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
  • Welding

  • High structural joint

  • Thermoplastic joining

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