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The ultrasonic welding of plastics uses high frequency sound waves to create frictional heat between thermoplastic materials. The welding tool (Sonotrode) couples with the part to be welded and moves it in longitudinal direction. The part to be welded remains static. Now the parts to be welded are simultaneously pressed together, using pneumatic press.

The simultaneous action of static and dynamic forces causes fusion of the parts. Localized friction heat is generated at the joint area creating a joint between two parts.

This process happens in a very short period of time (Generally within seconds). The primary requirement is that both working pieces should have near equivalent melting point. The joint quality is very uniform because the energy transfer and the released internal heat are limited to joining area, which causes very strong joint.

While designing the components to be welded together, the final shape of the joint can be decided by carefully designing the Horn (Sonotrode) Shape.

Various types of horn can be designed as per need, however following are the most commonly used.

1. Dome shaped 
2. Rosette shaped
3. Knurled

Advantages of Ultrasonic Plastic Welding

Ultrasonic welding has numerous advantages including speed, weld quality, weld strength, consistency and efficiency.

It is environmentally safe as there are no chemicals to be used in the process, less energy requirement and is computer controlled.

Process requires less manpower and time.

Equipment-

Boosters		Controller		Power Generator & Hand Gun

Ultrasonic plastic welding equipment consists of

1. Ultrasonic welding generator
2. Ultrasonic welding transducer
3. Booster
4. Horn (Sonotrode)

Applications of Ultrasonic Plastic Welding

Automotive

1. Instrument cluster
2. Inner door panels and door trims
3. Tail Lights
4. HVAC staking
5. Glove boxes
6. Spoilers
7. Front/ Rear bumpers
8. Central console

House wares/ Appliances

1. Refrigerators
2. Washing machines
3. Dishwashers
4. Hot plates
5. Vacuum cleaners
6. Electric toothbrushes

Novelties

1. Toys
2. Photo Albums 
3. Sports Accessories

Medica

1. Disposables
2. Catheters
3. IV Components
4. Containers

Computers/ Electricals/ Electronics

1. Housing
2. Connectors
3. Switches
4. Calculators
5. Batteries
6. Flash cards

Home Entertainment

1. TV
2. Music Systems
3. CD/DVD Players

Packaging

1. Zipper Bags
2. Grocery bags
3. Containers
4. Pour Spouts