Ultrasonic weld.
Plastic joining.
Sub-second cycle.
Ultrasonic welding process. High-frequency vibration melts plastic at joint. Sub-second cycle, automated, repeatable. Standard for high-volume plastic assembly.
Key principles.
20-40 kHz vibration
Ultrasonic energy creates frictional heat at joint.
0.5-2 second
Cycle time 0.5-2 seconds. Production-friendly.
Triangular ridge
Triangular feature concentrates ultrasonic energy.
Most thermoplastics
PP, ABS, PC, nylon, PEEK. Most thermoplastics.
Automation
Easy to automate. Fast cycle.
$10-30K
Equipment investment. Production-justified.
FAQ
Energy director design?
Triangular ridges (60-90° apex angle, 0.4-0.8 mm height) on one surface. Standard design.
Cycle time?
0.5-2 seconds typical. Faster than vibration welding, slower than spot welding.
Material compatibility?
Most thermoplastics weld. PP, ABS easy. PEEK premium. Some materials require specific frequencies.
Production rate?
Tens of thousands per hour with automation. Standard for high-volume plastic assembly.
Tooling cost?
Horn (sonotrode) $1-5K per design. Designed per part geometry.
Strength vs other welding?
Comparable to vibration welding. Stronger than adhesive. Slightly less than hot plate.
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