Ultrasonoic Welding
Ultrasonic Welding is a process used to join materials—particularly plastics and certain metals—by applying high-frequency ultrasonic vibrations (typically between 20 kHz to 40 kHz) to the materials being held together under pressure. The vibrations create localized heat through friction at the joint interface, causing the materials to melt and bond without the need for external heat or filler materials.
Working Principle
Clamping: Two components are positioned and held tightly together.
Vibration Transmission: High-frequency sound waves are transmitted through a welding horn (also called a sonotrode).
Localized Heating: The friction caused by the ultrasonic vibration at the interface generates enough heat to soften or melt the materials.
Bonding: The vibrations stop, but pressure is maintained to allow the materials to cool and solidify into a strong weld.
Suitable Materials:
Thermoplastics, such as ABS, PP, PE, and PVC
Thin metals, like aluminum and copper (commonly used in battery and electronics industries)
Advantages of Ultrasonic Welding
No need for adhesives, screws, or filler materials
Very fast process
High precision and minimal thermal damage to surrounding areas
Ideal for mass production
Applications
Automotive plastic parts assembly
Electronics components manufacturing
Sterile medical packaging (e.g., sealed bags)
Face mask production
