Ultrasonic Spot Welding

Ultrasonic spot welding is where plastics are subjected to binding at certain points without the need of a specific joint design.It is commonly used to apply sturdy structural welding points in multiple parts, such as extruded sheets or plastic parts of complex shapes.

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Ultrasonic spot welding is widely employed to manufacture vacuum sealed blister packs in order to get an airtight closure to avoid tampering. Most thermoplastics can be spot welded using ultrasonics.

A custom-made sonotrode penetrates the top layer (the thinner of two parts) and fuses them together. The displaced molten part is then entrapped into a custom-shaped heading on a spot of the top layer, welding at an interface level. This heading’s diameter is on average three times as thick as the first stratum — i.e. a 1mm thick upper part will have approximately a 3 mm raised ring, and a height up to 1mm. The bottom side will show no signs of indentations or markings.

Composite sonotrodes with interchangeable tips are available as standard spot welding components. Tip shape selection and use is quick and simple, allowing for items with a 3 mm thickness to be soldered this way. The bottom layer can be thicker than the top one. The spot binding process is versatile, fast and easy to use, with a manual handgrip that facilitates maneuverability.

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Basic Guidelines for Ultrasonic Spot Welding

• Low pressures
• Medium to high amplitudes
• Rigid support placed directly under the contact spot

More Information about Sonic Italia’s Ultrasonic Solutions

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