Ultrasonic welding uses energy operating at certain frequencies to create vibrations, which generate heat. This heat allows items held together under pressure to be welded into a solid joint. The use of ultrasonic welding is not only a step forward in the manufacturing process, but a massive advance in employee safety & protection of goods.
Consumer demand has pushed manufacturing across all industries to never-before-seen levels. The race to keep up has never been greater. As such, manufacturing processes have had to keep up in a way that has demanded:

  • greater efficiency
  • more attention paid to cost-cutting measures
  • greater attention to expediting processes
    In the face of such demands, ultrasonic welding is often ideal. More often than not, weld times can take a few seconds at the LONGEST. Furthermore, because precision can be achieved at great speeds, it ends up being an ideal track for facilities looking to expand automation.
    Using ultrasonic welding is also beneficial as it sits well with clients. It shows that they are working with a company who is willing to invest in technology whose aim is all about efficiency without sacrificing quality control. Everything from auto, medical devices, electronics, product packaging, and component housing all utilize ultrasonic welding, which means that its possibilities are near endless.
    Defaulting to ultrasonic welding in these (and other) industries makes the most sense as it ends up being the premier solution to do things that traditional welding techniques cannot:

  • the ability to join dissimilar materials
  • cause less damage to surface finishes
  • joining thinner, lightweight materials
  • lowers the introduction of contaminates & prevents contamination
  • creates fast, sanitary hermetic seals
    Ultrasonic welding is fast, incredibly adaptable, and gives the operator greater control of the process. It also allows for fairly easy training, making it unnecessary for current personnel to be replaced. There is also a variety of materials that are compatible with ultrasonic welding that make it quite adaptable to a number of industries. These include:

  • synthetic fabrics
  • metals
  • ceramics
  • plastics
  • glass
  • thermoplastics
    There are some disadvantages to ultrasonic welding. Perhaps the most consequential would be that it is not the best process for materials with higher melting points. The longer the time it takes for materials to reach their melting point and reach a welding effect, the heat will have been on the surfaces for an extended period of time. The prolonged exposure ultimately leads to a compromise in the integrity of the materials being joined and a likely failed weld.
    However, the truth is that most companies will not make the investment to bring in ultrasonic welding into their facilities, electing to outsource the work. Unfortunately, this is usually done for the lowest price. However, given the significance of the components and functionality of the finished items is, opting for the lowest bidder results in cases of getting what one pays for.
    Here at LoDan Electronics, Inc. in Illinois, our aim has always been to provide our clients with highly-complex interconnect systems and electronic assemblies in a cost-effective manner. Connect with our talented team and let us design and engineer an effective solution for your needs, with industry-leading ultrasonic welding as just one of the many capabilities we have to offer.