Ultrasonic welders have multiple uses. Frequently applied to fuse small- and medium-size thermoplastic parts, ultrasonic welding machines are used in automotive applications, computers, electronics, toys, textiles and house appliances.

How Do Ultrasonic Welders Work?

Plastic parts are joined together through pressure and high frequency mechanical vibrations, which create frictional heat that melts the plastic. When the vibrations cease, the plastic cools and solidifies. It’s a quick, cost-effective process because it doesn’t require connective bolts, soldering materials, adhesives or nails to bind materials together. However, whether two items can be ultrasonically bonded together or not all depends on their thickness.

What Are The Advantages Of This Type Of Welding?

Ultrasonic welders are fast, often in one second or less. Another advantage is that a ventilation system isn’t required to remove heat or exhaust. Ultrasonic welders are frequently used to assemble parts that are small and delicate. The advantage of joining complex parts with ultrasonic welders is that the welding equipment can be customized to fit the exact specifications of parts being welded. When welding plastics, the parts are nestled between an anvil and a horn, connected to a transducer. An acoustic vibration is then emitted to melt the point of contact between the parts. This process is a reliable, secured alternative to snap-fit screws and glue. It’s widely used with small parts, such as disposable medical tools, consumer electronics, cell phones and toys.

When Were Ultrasonic Welders First Used?

Ultrasonic welders for the application of rigid plastics started in the 1960s. The process of welding thermoplastic parts came about by accident. While working as a lab manager at Branson Instruments, Robert Soloff accidentally positioned an ultrasonic probe close to a plastic tape dispenser; the halves of the dispenser welded together. Realizing that ultrasonic energy could travel through and around rigid plastics to weld joints. Soloff went on to invent the first ultrasonic press, which was first applied to manufacturing toys and other small parts.

Ultrasonic welders have advanced through the years. Today, PAS ultrasonic welders run at 15 kHz, 20 kHz, 30 kHz, and 40 kHz frequencies. For further information, log onto HeatStaking.com.