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Many of our customers at MDI are interested in cutting costs of production on parts and components, particularly those made of thermoplastics. Applying generalized heat won’t work as it results in warping and distortion of the plastic along the “weld” location.

The use of our ultrasonic welding services provides a safe, effective and very durable weld that doesn’t result in any need for direct heat. This is not the same type of process used in film sealing that uses heat and pressure to create the seal.

To help to address common questions about our ultrasonic welding services, we have provided additional information.

1. Is the base plastic melted to form the weld?

No, it is not. When using ultrasonic welding the pieces to be joined are formed with small protrusions that direct the energy to these locations. These points melt and, with the pressure applied, form a joint. The base pieces of plastic are not melted, so there is no distortion. The small spikes are carefully positioned along the edge to provide a full seal.

2. Is it stronger than glue?

With our ultrasonic welding services, the final result is a joint on the plastics that is not only stronger than glue, but that will last much longer without deteriorating or letting go. Not only is it more durable but it is a faster process that can be fully automated and result in parts fully welded to each other in under a second.

In fact, ultrasonic welding technology is now used in automobile manufacturing with aluminum parts due to its strength and durability.

3. Can it be used on any plastics?

In general, ultrasonic welding can be used on all thermoplastics that are thin to moderate in thickness. In order to avoid the heat in the base piece, the melt has to occur very quickly, which makes very thick plastics problematic.

It is possible, however, to use ultrasonic welding for two different types of plastics. However, careful consideration as to the properties of those two plastics has to be used to ensure the process will create the weld strength necessary.