Things You Need To Know About Ultrasonic Plastic Welding

Ultrasonic plastic welding machines are widely used for welding plastic materials. Many plastic materials in our daily life are welded by ultrasonic plastic welders. Here we list some limitations of ultrasonic plastic welding you need to know for your project.

Material Limitation

Not all plastics can be ultrasonically welded, which is the biggest limitation of ultrasonic welding. Some plastics have good welding performance, while others have poor welding performance, and ultrasonic welding is generally only suitable for welding between the same or similar plastics. Therefore, once the ultrasonic welding process is selected, the product plastic material cannot be easily changed.

plastic materials
ultrasonic welding line not uneven

Weldment Not removable

Ultrasonic welding is non-removable welding. If the product is welded with defects, it cannot be reworked. Once the two parts are ultrasonically welded into one, the parts cannot be reworked if the product is found to have quality problems.

Product Size and Shape

Ultrasonic welding is generally suitable for small and simple plastic parts. Larger plastic parts may require multiple welding processes. For plastic parts with complex shapes, it is necessary to design a corresponding ultrasonic welding sonotrode for welding, and sometimes the welding quality may be low.

plastic parts
plastic structure strength

Product Structural Strength

Ultrasonic energy is very large, which may cause damage to the plastic part itself due to the insufficient strength during the welding process, and may also cause damage to other parts inside the product. Therefore, when designing products, the strength of the plastic parts and the strength of other parts inside the product should be increased as much as possible, or the parts should be kept away from the welding area.

Why We Need Plastic Ultrasonic Welding

Compared with traditional welding, plastic ultrasonic welding is faster, lower cost, more efficient, and has higher weld strength. Its welded joints are as strong as the raw materials and are clean, contamination-free and mark-free. For most thermoplastics, ultrasonic plastic welding is undoubtedly the best choice.


Things You Need To Know About Ultrasonic Plastic Welding
Things You Need To Know About Ultrasonic Plastic Welding

How does ultrasonic plastic welding work?

Ultrasonic plastic welding uses the piezoelectric effect to convert electrical energy into sound energy, and then into mechanical energy of high-frequency vibration of the welded object to complete the welding. Under the action of mechanical energy, welded plastic vibrates at high frequencies to generate heat, and the weld seam melts and solidifies into a new molecular structure. Finally, the weld strength is comparable to the raw material.

how to use an ultrasonic welder3

Adjustment method of ultrasonic welding machine

1. Connect the ultrasonic circuit and control circuit between the welding machine and the frame respectively.
2. To ensure safe operation, the ultrasonic welding machine must be grounded reliably.
3. Connect the air pipe of the external air source to the air filter of the ultrasonic welding machine.
4. Install the ultrasonic welding system, the converter is connected to the booster, and the booster is connected to the welding sonotrode.
5. Align the teeth of the welding sonotrode with the bottom mold and adjust the level of the sonotrode. Finally, lock the flange and adjust the welding gap.

Suggestions: The ultrasonic welding machine should be placed on a solid and level workbench, and a space greater than 150mm should be left behind the machine to facilitate ventilation and heat dissipation.

Where is ultrasonic plastic welding used?

The ultrasonic plastic welding machine is suitable for ABS, PP, PE, PC, PUC, PMMA, PS, PPS, PBT, PETG, and other plastic materials, and is also used in plastics, electronics, electrical appliances, auto parts, packaging, environmental protection, medical equipment, stationery, daily necessities, plastic toys, sporting goods, communication equipment, and other industries.


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