Below are basic explanations of how our processes work. All of our processes are clean, efficient, non-contaminating and require no consumables (adhesives, clips).

How does ultrasonic assembly work?
Ultrasonic welding is an assembly process for the mass production of a very wide range of quality products. It is mainly used for the welding of thermoplastic resins of all types and shapes in a great range of industries.

Ultrasonic Plastic Welding System converts 50Hz electric input to 15/20/30/KHz electric energy, which transforms this electrical energy into mechanical vibratory energy. This vibratory energy is delivered to the work piece through an acoustic tool/horn to generate localized heat under pressure. Frictional heat cause part interface to melt and fuse, creating a strong molecular bond.

	Near field welding With an ideal part design the contact of the horn to the plastic part will be as close as possible to the welding zone. We talk about near field welding in a distance of up to 6 mm. With this technology the best results are obtained in all thermoplastics.
	Far field welding In this technology the contact of the horn to the plastic part is further from the joint welding area. The thickness of the upper plastic part transmits the ultrasonic energy to the joining point. It is the extension of the horn and behaves to the same physical laws. Far field welding is only applicable as a second choice to near field welding.
	Staking/Riveting The horn is transmitting the mechanical vibration energy to the stud. The final head shape is designed into the horn face. The volume of the head corresponds to the shaft volume. Special attention must be given to wear of the horn point - especially in processing abrasive materials.
	Embedding In most cases the horn works directly on the metal part. The to be embedded part represents the lengthening of the horn. In other words it gets stimulated by the horn to vibrate with the same frequency and the same amplitude. In this manner the heat energy between the surface of the to be embedded part and the surface of the plastic part becomes effective.

How does hot plate welding work?
Hot plate welding utilizes a temperature controlled heat platen assembly, which is introduced between the two parts to be assembled. All items are brought together, and the melting cycle is started. The parts are melted for a pre-set time to displace enough plastic for surface preparation and to properly heat the subsurface of the joint area. The parts are then separated, and the heat platen is withdrawn. Both halves of the holding fixtures are brought together against stops for the proper amount of seal time and seal depth.

How does spin welding work?
Spin welding is a process that joins circular thermoplastic parts by bringing the part interfaces together, under pressure, with a circular, spinning motion. One part is held stationary in a fixture, while the other is rotated against it under pressure. The frictional heat that is generated causes the part interfaces to melt and fuse together, creating a strong, hermetic seal.