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Ultrasonic Plastic Welding














Ultrasonic technology in the plastic sector: plastic is definitely the most commonly used material in almost all sectors nowadays.

For the same reason, this is the sector where the ultrasonic technology use is the most widespread.

In fact, ultrasonic welding and cutting represent the fastest, cheapest, most precise and effective technology for this material.

Sonic Italia internally  manufactures its own sonotrodes with special designs, following each application requirements.

These sonotrodes are implemented on ultrasonic cutting and welding machineries, accurately studied according the customer’s needs.

Ultrasonic process of plastic materials

By using the ultrasounds, a plastic component is welded at a molecular level thanks to the vibrations issued by the sonotrode.

The frequencies of the sonotrodes may vary from 20 Khz30 Khz35 Khz up to 40 kHz, with the amplitude values from 50 to 5 µm .

Vibrations are directed in a specific manner by the use of energy directors with special designed customized following the application requirements.

The contact area between the plastic material and the sonotrode is thus welded by the frictional heat generated by the vibrations.

The structural design of the parts and the shape of the area to be welded are very important, especially if the sealing and strength requirements have to be met in the process of mass production.

Advantages of the ultrasonic technology 

Ultrasonic technology advantageously replaces the classical methods of assembly, eliminating the use of solvents and adhesives.

    • Short welding times (in the order of tenth of seconds)
    • Aesthetic perfection
    • Waterproof weling stable for a long time
    • Labor savings
    • Mechanical strengthSafe: ultrasonic components are cold
    • Energy-efficient
    • Flexibility 
    • Possibility of welding even in the presence of foreign bodies
    • Excellent mechanical seal

Traditional applications in the plastic field

Thermoplastic materials are common in a wide variety of fields.

Applications where ultrasound is better performing are:

  • Electronic
  • Appliance
  • Military
  • Office supplies
  • Toys
  • Optical
  • Precision mechanics
  • Paper industry
  • Sport equipment
  • Medical industry
  • Automotive industry

Ultrasonic welding system plastic component

Semi-automatic system with rotary system and pick and place.

Ultrasonic insertion

With ultrasonic technology is it possible to insert specific brass parts, that it is possible to find in the market.

Micro welding on electric board on a rotary plate

Rotary system of ultrasonic microwelding on electric boards. Ultrasonic welding does not ruin the circuits because all the energy is concentrated in the contact point.

Conveyor belts spot welding

In the poultry industry our guns are used to repair the conveyor manure belt and/or eggs conveyor belt easily and, most of all, in loco. Sonic gives every leading company in the the poultry sector, in Italy and all over the world.

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