Ultrasonic welding: the quintessential plastic welder
Ultrasonic welding machines’ quick, clean process uses high-frequency vibrations and pressure instead of heat to melt and weld plastics, which provides many benefits.
One of the most rapidly developing fields in the welding industry is ultrasonic welding, a process that uses high-frequency vibrations instead of applied heat to melt plastic. Small- and medium-sized pieces of plastic are welded together with ultrasonic welding machines because the machines create frictional heat that melts the plastic together. After the plastics are melted and the vibrations stop, the plastic quickly cools and solidifies.
There are many benefits of electronic welding, including that the process is quick and repeatable. Further, the process does not “consume” any additional materials, which means it does not require screws, nails, bolts, soldering materials, glues or other adhesives. Ultrasonic welding machines may even be used to create hermetic seals, because the finished pieces are so strong and clean. An added benefit is that no ventilation system is required because no heating is involved.
It is through pressure and high-frequency mechanical vibrations (15 kHz to 40 kHz) that plastic is melted into a solid-state weld. Most preferred ultrasonic welders run at 15 kHz, 20 kHz, 30 kHz and 40 kHz frequencies.
To begin the process, two thermoplastic pieces with similar melting points are placed in the ultrasonic welding machine. Next, high-frequency vibrations are applied directly to the joint that is being welded. Because the vibrations are limited to the joint, only the joint – not the base material – is melted. Once the plastic is melted, the vibration is stopped, pressure is applied, and the pieces are melded together. The entire process is so fast and efficient, weld times can be less than a second long.
The ultrasonic welding process has become invaluable to many industries. They include the automotive, cosmetic, computer, appliance, toy, medical, electronics, textile, packaging and food industries. Ultrasonic welding is usually preferred in the medical-supply industry, because the no parts are contaminated by outside materials. Products processed with ultrasonic welding machines can even be used for “clean rooms” in hospitals. One of the most typical uses of ultrasonic welding is in the packaging and food industries, which also count on the contaminant-free, clean, quick process.
Ultrasonic welding has come a long way and is now one of the most progressive industrial techniques. It was in the late 1940s that ultrasonic waves were first used – mostly for cleaning. Then, in the 1950s, ultrasonic welding was introduced as a way to weld plastics and metals. In 1965, the patent for the process was granted to two men – Robert Soloff and Seymour Linsley. The popularity of ultrasonic welding began with the toy industry and has spread to a growing number of applications every year.
Today, ultrasonic welding is considered the leading assembly method for rigid thermoplastics. Models of ultrasonic welding machines include: ultrasonic hand guns; bench-top integrated ultrasonic welders; automation ultrasonic actuator heads and modular power supplies; and closed-loop process controls, like energy welding, distance welding, time welding, force welding, automatic frequency tuning and variable-amplitude output control. There are microprocessor and standard-time models available, as well as tools of the trade, like ultrasonic horns, fixtures, converters and boosters for all makes, models and brands of ultrasonic welders.
When it comes to companies that provide plastic assembly solutions, look for top-notch service and technical support and a company that meets each customer’s individual needs. For superior ultrasonic welding machines, check out Plastic Assembly Systems at www.heatstaking.com.
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