Types of joining

Ultrasonic vibratory energy is used in several distinct assembly and finishing techniques as described below:

A.Welding

The process of generating melt at the mating surfaces of two thermoplastic parts. When ultrasonic vibrations stop, the molten material solidifies and a weld is achieved. The resultant joint strength approaches that of the parent material; with proper part and joint design, hermetic seals are possible. Ultrasonic welding allows fast, clean assembly without the use of consumables.

B.Staking

The process of melting and reforming a thermoplastic stud to mechanically lock a dissimilar material in place. Short cycle times, tight assemblies, good appearance of final assembly, and elimination of consumables are possible with this technique.

C.Inserting

Embedding a metal component (such as a threaded insert) in a preformed hole in a thermoplastic part. High strength, reduced moulding cycles and rapid installation with no stress build-up are some of the advantages.

D.Swaging/Forming

Mechanically capturing another component of an assembly by ultrasonically melting and reforming a ridge of plastic or reforming plastic tubing or other extruded parts. Advantages of this method include speed of processing, less stress build-up, good appearance, and the ability to overcome material memory.

E.Spot Welding

An assembly technique for joining two thermoplastic components at localised points without the necessity for preformed holes or an energy director. Spot welding produces a strong structural weld and is particularly suitable for large parts, sheets of extruded or cast thermoplastic, and parts with complicated geometry and hard-to-reach joining surfaces.

F.Slitting

The use of ultrasonic energy to slit and edge-seal knitted, woven and non-woven thermoplastic materials. Smooth, sealed edges that will not unravel are possible with this method. There is no "bead" or build-up of thickness on the slit edge to add bulk to rolled materials.

G.Textile/Film Sealing

The use of ultrasonic energy to join thin thermoplastic materials. Clear, pressure-tight seals in films, and neat, localised welds in textiles may be accomplished. Simultaneous cutting and sealing is also possible. A variety of patterned anvils are available to provide decorative and functional "stitch" patterns.