Ultrasonic Welding Services

Ultrasonic welding is a widely accepted thermoplastic assembly method used in numerous industries, including automotive, medical, electronics, telecommunications, and many others. This economical process can significantly reduce your assembly costs without sacrificing structural integrity. Mueller Custom Cut offers this value-added capability for unprecedented repeatability, reliability, and accuracy.

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What Is Ultrasonic Welding?

Ultrasonic welding causes two thermoplastics to fuse through acoustic vibrations. Combined with applied force, the conversion of electrical energy into mechanical motion generates enough frictional heat to melt two surfaces together, creating a durable molecular bond.

Here’s how the ultrasonic welding process works:

  • Parts in the fixture: The two thermoplastic parts to be assembled are placed in a supportive fixture, one on top of the other. A metal component called a horn is lowered until it comes in contact with the upper part. This applies a controlled force to both parts until they clamp together.
  • Welding: The horn vibrates vertically at ultrasonic speeds of 20,000 to 40,000 times per second (20 to 40 kHz). The vibration affects a limited point of contact, with movements measured in thousandths of an inch (microns). When the temperature reaches the material’s melting point, the parts fuse.
  • Hold time: The vibration stops, but the clamping force remains for a predetermined length of time. Improved joint strength and airtightness may be achieved by increasing the pressure during this hold time.
  • Project completion: Once cooled and solidified, the melted parts join into a solid-state weld, as though molded together from the start.

If ultrasonic welding sounds like the right assembly method for your application, please contact us today at (704) 926-5827 to learn more.

Material Considerations

Many types of thermoplastics are eligible for ultrasonic welding. For a successful bond to occur, the materials of both parts must be chemically compatible. Otherwise, there won’t be a molecular bond, even if the parts melt together. In general, similar amorphous polymers are compatible with each other, while semi-crystalline material is only compatible with itself.

Melting point is another important aspect of material compatibility. For instance, an acrylonitrile butadiene styrene (ABS) part and an acrylic part will likely weld successfully because their melting points are within 40 degrees F of each other. However, polyethylene and polypropylene are chemically incompatible because their molecular structures differ too much. Even when two materials are compatible, other factors may affect their weldability, including any lubricants, fillers, pigments, and flame retardants present.

Rest assured that Mueller is extremely knowledgeable about what materials are compatible with one another for ultrasonic welding purposes. If you have any questions, feel free to reach out to us online or call (704) 926-5827.

Benefits of Ultrasonic Welding

This product assembly method offers numerous advantages:

  • Ultrasonic welding is a fast, clean, efficient, and repeatable process.
  • It’s possible to create strong, integral bonds while consuming minimal energy.
  • No external heat, mechanical fasteners, solvents, or adhesives are required.
  • Ultrasonic assembly is possible with materials that are difficult to weld any other way.
  • Rapid heat dissipation allows the process to cycle considerably faster than other welding methods.
  • The assembly system’s tools and applications can be changed quickly for excellent flexibility and versatility.

To take full advantage of these benefits, call Mueller at (704) 926-5827 to arrange ultrasonic welding services with our experienced company.

Why Choose Mueller Custom Cut For Ultrasonic Welding?

With over 80 years of experience, we have proven our ability to meet our customers’ needs time and again. We work with over 120 suppliers and prioritize our relationships with each one. No matter the size or scale of your ultrasonic welding needs, our services have you covered.

Mueller is ready to serve you, so give us a call at (704) 926-5827 or request a quote online to get started.

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