At its most basic definition, ultrasonic welding, also referred to as USW, uses energy operating at certain frequencies to create vibrations. These vibrations lead to the generation of heat. This heat allows items held together under pressure to be welded in 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 alternative materials as a cost-cutting measure
  • greater attention to safety in the name of expediting processes
    Ultrasonic welding is being used more as it is often the ideal welding option based on the materials being used. More often than not, weld times can take a few seconds at the LONGEST. Furthermore, due to the precision that can be achieved at great speeds, USW ends up being an ideal option for facilities looking to expand automation.
    Major industries that utilize ultrasonic welding include but are not limited to: computer/electrical, aerospace and automotive, medical, and packaging. Defaulting to ultrasonic welding in these 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
  • less damage to surface finishes
  • joining thinner, lightweight materials
  • lowers the introduction of contaminates & prevents contamination
  • creates fast, sanitary hermetic seals
    No discussion of manufacturing processes is complete without acknowledging the role of personnel safety. Is ultrasonic welding safe? USW needs to be operated according to established safety guidelines. Furthermore, machinery should be operated by trained personnel only. It is also advisable that anyone in the vicinity of the machinery should be made aware of any precautions they should take regarding eye & hearing protection.
    One thing that makes ultrasonic welding such a welcome addition to small- & large-scale manufacturing is its flexibility in terms of parts & materials for which it can be used. This means that clients from a variety of industries can be served well through precise & dependable build quality.
    But before a facility can fully transition to a ultrasonic welding operation, facility management should be mindful of the following:

  • does ultrasonic welding cause any disturbances to other equipment in a given space?
  • is ultrasonic welding difficult to integrate into current production lines?
  • what level of resources must be allocated to training & extra manpower for USW integration?
    Even if a company is not integrating ultrasonic welding themselves, their manufacturing partners may be heavily investing in the technology. How will this affect final products? What will change in terms of the latest versions of components? In truth, there will be a lot more questions than usual. This is where having the right manufacturing partner certainly pays off. Clients want to be sure that the products they invest in are being made to the highest standard & not just as a result of a general cost-cutting measure. Furthermore, clients want to be sure that their manufacturing partner has invested in the overall quality of their ultrasonic welding machinery, training of their personnel, and dedication to staying on top of the technology that makes it all seamlessly work.
    LoDan Electronics, Inc. in Chicago has a vast array of customized assembly capabilities including ultrasonic welding, and our record of success has made us a go-to name since 1967. Call us today to see how our expertise can help your next project go to the next level.