Advantages and Disadvantages of Ultrasonic Plastic Welding

What is ultrasonic welding?

Ultrasonic welding technology uses high-frequency vibration (ultrasonic) to precisely seal two thermoplastic components together in sub second time. Under precise pressure, the connection seals in less than 0.2 seconds.

Advantages of Ultrasonic Plastic Welding

Ultrasonic welding technology has the characteristics of fast welding speed, high welding strength, and good sealing performance. This is a suitable alternative to traditional welding/bonding processes. This process is very clean because it does not use harmful solvents or adhesives, and it also does not damage the product. This technology is also easy to implement in the production process and has a low failure rate. As rewards, all these advantages contribute to reducing production costs.

Disadvantages of Ultrasonic Plastic Welding

When the thickness and hardness of plastic parts increase, the power required for welding increases exponentially with the parameters of the plastic. This increases the manufacturing cost of ultrasonic welding machines. If the power requirement is too high, the design, manufacturing, and process effects of the audio system will create a series of difficult problems to solve. Therefore, this technology is more commonly limited to thin components such as fine wires, foils, and sheets. The current state of technology limits the joint form of ultrasonic welding systems to lap joints and is restricted by tool heads. Parts can only protrude within the size range allowed by the welding system. The form and size range of welding joints are limited.