Ultrasonic Welding

Ultrasonic welding uses the potential energy within the plastic itself, converting it to heat and sound. Parts are vibrated toward and away from each other. The constant motion heats and softens the plastics. Vibrations mix softened plastic surfaces together and it forms a physical as well as chemical bond if the plastics are selected correctly.

A sonic horn oscillates vertically and delivers the energy where it's needed by contacting the plastic part at a variable distance from the projection point, depending on the application. The part on the other side of the joint area rests on an energy-dampening anvil, ensuring the sonic energy remains in the weld zone. Tongue & groove joint design and location is very important in ultrasonic welding.

• Interference, or shear types of joints, involve welding a slightly larger part into a smaller one
• Shear joint designs are commonly used for semi-crystalline polymers, or when watertight seals or high joint strengths are needed

Interplex is YOUR SOURCE for Ultrasonic Welding. We developed many products for our customers using this complicated process. We can make it easy for your product to benefit from Ultrasonic Welding.

Ultrasonic welding of plastics has many advantages over other plastic-joining processes, including:

• Lower cost/ Greater Efficiency - eliminates the costs of consumables, produces repeatable, ERROR FREE results
• FAST - welding usually occurs in less than a second.
• Cleaner process - no consumables required, less risk of contamination 
• Greater reliability - adaptable to clean-room environments as well as high-volume production situations

Ultrasonic Welding: Applications & Uses

Interplex utilizes Ultrasonic Assembly for assembling all types of medical products:

• Filters
• Instruments
• Fluid vials
• Masks
• Surgical garments

Interplex can handle a wide variety of additional uses and applications of Ultrasonic Assembly, including:

• Attaching plastic components
• Inserting metal components into plastics
• Plastic Tubes and pumps - will not contaminate contents

Ultrasonic Welding is a Safe, Fast Process for High Volume Production

Ultrasonic welding is probably the most commonly used thermoplastic welding process.

• Very fast (fractions to a few seconds)
• Usually produces welds that are relatively free of flash
• Suitable for high volume production
• No Caustic chemicals
• Very Few Fumes