Types and applications of ultrasonic welding equipment

Ultrasonic cutting and welding equipment is frequently used to produce fabric goods. They are also used to connect thermoplastic components to metals like aluminium.

Ultrasonic energy is used to join, cut, pattern, and quilt synthetic fabrics containing no more than 40% natural fabric content.

Ultrasonic welding is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. High-frequency vibrations, combined with contact force, generate heat by friction at the mating surfaces. As a result, the plastic will melt and form a bond between the parts that are being joined.

Ultrasonic cutting is accomplished by pressing the vibrating horn against a fixed anvil and allowing the horn to push through the fabric, sealing the edge. This method is used to punch holes, cut pre-cut patterns, and cut fabric strips to pre-determined lengths. Food processors slice their products as they come out of ovens, using ultrasonic knives that vibrate 20,000 times per second. The high-frequency vibration creates a nearly friction-free surface between the tool (knife) and the product, removing the possibility of sticking and pinching.

Ultrasonic welding equipment specifications

Ultrasonic cutting and welding equipment is made up of various parts:

· A power supply converts line power at 50 or 60 cycles to high ultrasonic frequency at 20 000 or higher cycles per second. These high-frequency electrical signals can change the frequency based on the ultrasonic stack (converter, booster, and horn).

· A pneumatically controlled press applies pressure to the welded parts and controls the horn’s movement.

· A converter is a device that converts electricity into mechanical vibrations with a high frequency.

· The booster transmits vibration energy, increasing its amplitude, and clamps the horn and convertor to the press.

· The vibration energy is delivered to the material to be worked on via a horn, usually manufactured from titanium or aluminium.

· An anvil or backup tool supports the work material and has channels to allow the horn to completely sever the material and seal the edge. Various ultrasonic welding fixtures hold the material in place. It is critical that the parts are aligned with the welding horn for a successful ultrasonic weld.

Ultrasonic vibrations are transmitted from the horn to the material during operation. This generates frictional heat and fuses the material at the point of contact. The material is cut through, and the edges are sealed at the same time when a cutting edge is used on the anvil.

Ultrasonic welding equipment applications

Ultrasonic welding and cutting are used to replace traditional fabric assembly techniques in clothing production in many ways.

Seams: Making seams or hems in disposable medical products is a common application. Medical garments, face masks, and other items fall into this category. A single row, double row, or triple row of stitches can be simulated using pattern wheels.

Sleeves and cuffs: To effectively weld sleeves and cuffs, cylindrical machines employ a cylindrical arm with a rotary stitch wheel and an ultrasonic system above the wheel.

Slitting or sealing: Ultrasonic slitters cut and seal the edges of synthetic or blended fabrics with precision. As a result, fraying and unravelling are almost completely eliminated.

Hand cutting: A hand-held cutter can cut straight lines or large radius curves.

Plunge cutting: A plunge cutter can cut ribbons, strips, and other materials to length.

Plunge sealing and cutting: Ultrasonic plunge sealing and cutting are performed by advancing single or multiple horns onto materials placed on a fixed anvil.

Adhesive bonding: Thermally activated materials are sandwiched between two non-thermoplastic fabrics, such as cotton, wool, or cotton-wool blends with little synthetic content. The ultrasonic vibrations cause the thermally activated adhesive to flow into the fabric fibres and join them together.

Ultrasonic welding equipment features

When used in the production of synthetic clothing and other fabric products, ultrasonic cutting and welding equipment is an excellent efficiency multiplier. Though woven and nonwoven fabrics are the most used materials for ultrasonic cutters and welders, other plastic and metal components may also be used in this process.

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How ultrasonic welding transformed plastic welding

Plastic welding, or any process that flawlessly bond thermoplastics, has been around for a long time. One of the most ground-breaking approaches developed for this practice is ultrasonic welding. Ultrasonic welding uses sound waves rather than heat or electricity to join two dissimilar components, resulting in a weld that does not require soldering, binders, or adhesives to keep two materials together.

The method was discovered in 1963 when Robert Soloff noticed that sound waves were not limited in the same manner that other plastic welds were. Instead of direct contact between the material and the applicator, an ultrasonic welder may send sound waves around corners and along the edges of rigid plastic. This enabled sound waves to locate the contacting seam that needed to be welded, allowing an ultrasonic weld to reach considerably smaller and tighter areas than conventional types of heat sealing.

Since then, ultrasonic welding has found widespread application in heat sealing and plastic welding applications. Today, ultrasonic welding has replaced glue and screws in various consumer goods, including cellphones and toys.

Because ultrasonic welding does not need a soldering substance or emit any heat or fumes, it is a very environmentally safe and efficient form of thermoplastic welding. In addition, ultrasonic welding, like several other plastic welding technologies, are completed in a fraction of a second. This means materials are bonded as fast as before but ultimately saves money over conventional heat-sealing procedures. Ultrasonic welding machines can also be easily customised to deal with very particular materials.

Because no external material is required, ultrasonic welding can be used in computer and medical applications where debris and foreign matter might have devastating consequences. Furthermore, because of its versatility and speed, ultrasonic welding has become one of the most widely used methods of plastic bonding today.

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How ultrasonic welding works

Ultrasonic welding is defined as the use of high-frequency vibration pulses to create an ultrasound of the component being welded. Then, the pieces are fused together under intense pressure, resulting in the weld’s solidity. The parts often used with this form of welding are made of plastic.

The vibrations created during ultrasonic welding enable the welder to merge the materials without nails, bolts, or other components to hold the sections together. Vibrations are used on thermoplastics while they melt, and the pulse acts like a magnet, drawing the pieces together to shock them. Ultrasonic welding is used on various materials. In metal welding, the process is referred to as friction welding. A welding sonotrode is a sort of horn that generates welding vibrations. The sonotrode causes the thermoplastic to soften, allowing it to be lined up and joined together. Every material used for welding has a varied level of strength.

When several projects must be completed simultaneously, ultrasonic welding is used. This type of welding is the most efficient and effective approach since a large amount of inventory is involved, for example, in the automotive and electrical industries. Metals, rigid plastics, and soft plastics may all be used during an ultrasonic welding procedure. Nowadays, because ultrasonic welding has been so effective in welding materials mentioned, the technology is being explored to see how well it would work with other materials.

To perform correctly, ultrasonic welding requires two pieces of material that can be joined together under high pressure. Next, an anvil is used to arrange the components where they need to be to bond. An ultrasonic stack is also required for the sonotrode horn to be tuned to the vibration. Following that, an ultrasonic generator with high A.C. power is needed to match the stack resonance. Finally, a controller is also required to keep the press moving and deliver the ultrasonic energy. Because ultrasonic energy has increased in popularity among many manufacturing organisations, you can be sure that ultrasonic welding will be employed for various bonding tasks in the future.

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If you have any questions about ultrasonic welding, you can get in touch with us today for more information on our products, services, and spares.

Plastic welding durability

Plastic welding has been around for decades and is used in the medical field, packaging, and automotive sector. Various elements determine its durability, but under ideal conditions, it can be extremely strong and long-lasting.

When done correctly by effectively preparing the welding area in advance, with the correct welding rod and repeated verification of various other factors, plastic welding may have as much as 98 percent of the parent material’s strength.

The purpose of plastic welding

Plastic welding applications are used in various sectors, most notably the automobile industry, particularly for bumpers that need to pass strict safety tests.

Factors that influence durability and strength

Plastic welding may be exceedingly strong and long-lasting if done correctly. However, various elements can influence its longevity, ranging from the material used to the welder’s expertise. Frequently, poor welding technique is blamed for reduced durability expectations.

Factors that result in reduced durability of the plastic weld include but are not limited to:

  • Selecting the wrong welding rod
  • Inadequate preparation of the area
  • Incorrect temperature
  • Material too weak to handle plastic welding

Preparing the area

Sufficient cleaning of the area to be welded is critical. As a result, the parent material must be thoroughly cleaned and stripped to remove all traces of paint, oil, grease, or UV deterioration and ensure an effective plastic weld.

Additional preparation includes selecting the right welding technique you plan to use. For example, for short weld runs, pendulum welding is used, while speed welding is used for longer runs. Preparing the weld correctly in advance is critical to the plastic weld’s longevity.

Testing durability

Choosing the appropriate rod from a rod test kit is critical for testing durability. In addition, small strips of the parent material can also be welded as a test. This second method is crucial in assessing whether the material is suitable to weld properly. However, tensile testers are most typically used to measure strength, and several parameters are evaluated in a weld to ensure durability.

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Plastic welding through ultrasonic applications

There would be no electrical cable insulation or plastic containers without plastic welding, making it an ideal option for limitless creation.

Plastic welding creates a molecular bond between two compatible thermoplastics. Ultrasonic welding is one of the methods used to weld plastic.

Ultrasonic welding

Ultrasonic plastic welding uses heat generated through high-frequency acoustic vibration. As a result, high-frequency electrical energy is converted into high-frequency mechanical motion. That mechanical motion, combined with applied force, creates frictional heat at the joining points, resulting in a molecular bond in a matter of seconds.

Benefits of plastic welding

  • No messy or hazardous consumables are used in plastic welding.
  • Plastic welding generally doesn’t require specific surface preparation steps.
  • A plastic weld is permanent, unlike mechanical fasteners and adhesives.
  • Plastic welds are lightweight and create leak-tight, airtight seals.

Advantages of ultrasonic welding

  • Very fast process of typically less than a second.
  • Ultrasonic welding equipment offers advanced control and monitoring features.
  • Ultrasonic welding is an economical process.

Plastic welding tips

  • Always weld like-plastic with like-plastic.
  • Ensure your workspace is well-ventilated.
  • Use heat-resistant gloves and wear long-sleeved protective clothing.
  • Clean the welding plastic with soap and water and remove debris and dry plastic.
  • Keep the pieces of plastic together with a clamp and tape.
  • Form the joint before you turn on the torch.

Types of plastic welding seams

  • A fillet weld is one of the most frequently used seam geometries produced by welding two pieces that meet in a T-joint.
  • An interior corner seam is often used in difficult-to-reach locations.
  • V-seams are created when the workpieces are bevelled at the correct angle to each other.
  • X-seams or double V-seams combine two V-seams on each side of the parts to be joined.
  • Lap seams are generally used for plastic sheets arranged on top of each other.

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If you have any questions about ultrasonic plastic welding, you can get in touch with us today for more information on our products, services, and spares.

Understanding ultrasonic welding

Ultrasonic welding is a process that uses the ultrasonic vibration of high frequency to weld two thermoplastics together. It is a common industrial technique to bind without the need for soldering materials or adhesives.

It is used to create plastic-to-plastic joints, install windows in housing, and insert mechanical fasteners into plastic injection moulded parts.

What sets ultrasonic welding apart from standard welding?

There’s no waiting time with ultrasonic welding for machines to warm up or the materials to be heated. In addition, ultrasonic welding creates air and watertight seals, consumes less energy, and leave no solvent or filler waste.

Furthermore, the ultrasonic welding process happens in seconds, saving time and, subsequently, production costs. Ultrasonic welding is a safer process compared to other welding methods since there are no fumes from soldering. Ultrasonic welds are as strong and durable as standard welds. They can be used to bond the metal in less time and at lower temperatures, making it ideal for the automotive industry, where there’s a high demand for cost and weight limitations.

Material consideration

When bonding two thermoplastic parts through ultrasonic welding, the materials must be chemically compatible to ensure a molecular bond. Thermoplastics with the same chemical properties will weld to themselves, while different thermoplastics are only compatible if their melt temperatures are within 6°C and have a similar molecular structure.

Joint design considerations

For the best assembly results, the joint design of the mating pieces is critical. Each part’s joint design relies on several factors, including the type of plastic and shape of the part. The basic requirements in joint design calls for a small initial and uniform contact area and means of alignment.

Advantages of ultrasonic welding

Ultrasonic welding is an assembly process that is fast, clean, efficient, and repeatable. In addition, it produces strong, integral bonds and consumes very little energy. It is more environmentally friendly since it uses no solvents, adhesives, mechanical fasteners, or external heat to create a solid and clean finish.

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If you have any questions about ultrasonic welding, you can get in touch with us today for more information on our products, services, and spares.

The Plastic Manufacturing Revolution

Joining Plastic Processes

Plastic joining machinery can be hard to find, especially if you are looking for top of the range equipment.

Joining plastic is a process which requires machinery that can effectively and reliably weld plastic together, which is durable and long-lasting.

Of course, depending on what type of machinery you buy, there will be an increase or decrease in the labour needs and equipment costs.

Adding to this, each process has limitations on the size and kinds of plastic that can be joined.

If you are looking for a plastic manufacturing equipment company who will deliver top quality machinery, M.E.E has got you covered.

There are 8 ways in which plastic is able to be joined through the use of high-tech joining plastic machinery.

These are mechanical fastening, fusion bonding, hot gas welding, vibration welding, solvent bonding, ultrasonic welding, induction welding and dielectric welding.

Mechanical Fastening

One of the simplest ways to join plastics is by using a fastener, such as a hinge, in order to hold plastics together.

This technique requires the plastics to be stronger as they need to be able to hold during the manufacturing process.

On top of this, they need to be able to work under stress when used and if they are not joined properly, they could break.

If rigidity is important for your business in terms of plastics then this form of joining is not for you.

Fusion Bonding

Fusion bonding is the process of taking pieces of plastic and welding them together. This form of high-tech joining plastic machinery is precise in measuring and welding plastic parts together.

The melting process puts the separated plastic parts together, melting them into each other. As this happens, the plastic joining machinery is ensuring that the surface of the part is smooth.

The entire process, from start to completion, is quick which is a benefit as multiple parts need to be made during the workday. This allows for demand to be met as the supply is high.



Hot Gas Welding

This form of plastic joining is a slow process as it is the heating of a thermoplastic rod, which will be used to melt parts of plastic, which will then be placed together in order to be joined.

This type of joining plastic machinery needs highly skilled labour to effectively join parts.

Another factor is that if the parts are complex, the time it will take to join parts will be much longer.

If you are looking for shorter manufacturing times, or if you are working with intricate parts, then hot gas welding is not the choice for you.

Vibration Welding

The way that vibration welding works is that parts are placed together, with one part being vibrated at a high rate in order to produce friction.

Friction will allow the parts to heat up and form perfectly together. Where a plastic manufacturing equipment company may sell such machinery, this technique is used more for larger parts.

The reason for this is that these large parts would not be able to be joined in any other way. Using other plastic joining machinery would prove to be a failure.

Solvent Bonding

Solvent bonding uses solvents which are placed on plastic parts to soften them. As the solvent vaporises the parts will be joined.

Heating decreases the time the process will take to work. Too much pressure placed on the parts will affect the shape, too little pressure will not allow the parts to properly join.

This joining will only work after a few hours may be needed in order to ensure that the parts are properly fixed together.

Ultrasonic Welding

Joining plastic machinery which M.E.E supplies, ultrasonic welding used vibrations, similarly to vibration welding with a tool called a horn.

This technique vibrates two pieces of plastic together which will heat them up, melting the parts together.

The benefit of using ultrasonic welding is that this high-tech joining plastic machinery allows different types of plastic materials to be fused together.

Induction Welding

Induction welding uses a metal insert which will allow two plastic parts to be able to fit together.

The metal insert is heated using a magnetic field which will allow the plastic parts to be welded together.

This form of joining plastic machinery is can also use a different sort of bonding when ferrite is utilised for welding.

Molecular friction is used in order to allow both plastic parts to join correctly.

If metallic particles are chosen, then the plastic joining process will be using an alternating magnetic field to heat the part.

Dielectric Welding

This form of welding uses high voltages as well as frequencies, which will break the plastic parts down in order to fuse the plastic together.

Usually used on thin sheets of plastic, this plastic joining equipment allows for a quick joining process which works best for PVC materials such as pipes, sides, tubes and also blood bags.

PVC is a widely used plastic, where almost all piping is made up by the material.

Dielectric welding is able to produce quality PVC items in a short amount of time, keeping them in a reliable condition.

If you are looking for a dietetic welding machine which produces quality products, you should get into contact with M.E.E.

Benefits Of Manufacturing Plastic Parts


Choosing to purchase from a plastic manufacturing equipment company that is reliable will save you money as they will be providing you with competitive prices, as well as giving you products which are good quality.

Joining plastic machinery is cost-effective in terms of not being pricey, while at the same time being able to fuse products at a faster rate.

On top of this, parts are not hard to find and are also low in price which means that maintenance costs will be a minimum requirement.

In terms of production, the energy consumption is much lower than other types of manufacturing machinery.

Time Efficient

Production costs will be low and production time will be decreased with the dyeing process being able to be done before the welding and melting process.

Plastic joining machinery has been designed to ensure that surfaces are kept safe and smooth when joining multiple pieces of plastic together.

Fusing has even been improved meaning that even after pieces have been welded together, the time it takes for it to set has been decreased.

High-tech plastic machinery has been able to remove a lot of steps in the once long list of tasks of plastic joining.

The more you are able to produce with your joining plastic machinery, the more you will be able to supply.


In terms of structural strength, the use of plastic joining allows the material to be one of the strongest.

Being strong, lightweight and multipurpose, plastic is leading the way in terms of becoming the favoured material in terms of its functionality.

Plastic manufacturing equipment Johannesburg is able to provide your business with the tools needed to produce this popular material.

The rise of use in plastic is ever-growing, with demand soaring.

High-tech plastic machinery will be able to produce high-quality plastic products in a more faster and efficient way.


A major benefit, especially in terms of our environmental impact, is that plastic products can be reused in a multitude of ways.

Plastic can be easily transformed into a lot of different products unlike other materials used in major industries such as steel.

Using high-tech plastic machinery will also help keep the shape, strength and overall look of plastic in tip-top quality.

Your businesses overall expenditure will drop as well-meaning that you are not only saving the environment, you are also cutting costs effectively.

Increased Lifespan

Plastics have a much higher chemical resistance compared to metals which means that they will last a lot longer.

This also allows the reuse of plastics, as mentioned, where plastic joining machinery can reuse plastics in order to reproduce new plastic materials.

Like its recyclability, plastic will cut your costs down as you will not have to search for new plastic materials time and time again.

Of course, there will come a time when you will have to replace plastic as it will eventually break down.

If your business is looking to start working with plastics, contacting a plastic manufacturing equipment company, such as M.E.E will ensure that you are getting the best machinery possible.

CAD System And CNC Machines

M.E.E uses a CAD system, alongside their dedicated team of qualified specialists, in order to efficiently develop and design their joining plastic machinery.

The CAD system is used to develop and design a lot of products and equipment, including bending and moulding steel into shapes.

CNC machines use a CAD system in order to precisely create products and equipment effectively.

What Does CNC Machinery Do?

CNC machines use a preplanning system such as CAD, which will tell the machine how to precisely design a product.

Everything from speed to coordination has all been processed, ensuring that the CNC machine will deliver a perfect design, all in a shorter amount of time.

M.E.E uses the CNC machine in order to create their high-tech joining plastic machinery, ensuring that their equipment and machinery is state of the art and completely uniform.

This will also ensure that you know you are working with a plastic manufacturing equipment company that will deliver machinery that is of high quality.

CAD system will tell the CNC machine exactly what to create, as well as how much detail it requires.

After this, through the programming of specialist employees, your machines will be able to be made in front of your eyes.

How Great Is CNC Machining?

The reason as to why M.E.E uses CNC machining is because it allows them freedom in terms of what they can create as well as decreasing the production time completely.

The plastic manufacturing equipment company is always looking forward and has found that if they are able to design your products more effectively, efficiently and more precisely, it is a win-win relationship.

The faster they are able to produce your equipment the faster you will be able to receive it.

If you are looking for plastic joining machinery which is completely flawless, then looking into M.E.E and their products will get you what you want.

With conventional manufacturing, equipment which is being produced will have to be moved from one station to the next in order to be made.

CNC machines stop this step as it is able to completely develop your joining plastic machinery at one station in a much shorter amount of time.

Quality and quantity can both be attained when using a CNC machine.

Your business will be for the better as your plastic joining machinery will be top quality, highly functional and ready to use as soon as you get it.

Another big benefit of using M.E.E is that there is a guarantee that your supply will reach you in time and with the right amount as CNC machines are able to produce equipment in high quantities over and over again.

Contact M.E.E For More Information

If you are looking for top-quality plastic manufacturing and high-tech plastic joining machinery, then you should take a look at M.E.E. Their range of equipment and machinery will ensure that your business is working at an optimum level.

Contact M.E.E for more information.

What is Ultrasonic Welding?

Plastic products in all shapes and sizes have become an important part of our world. With a wide range of applications, their importance is often understated. When it comes to welding plastics, particularly wherever uncommon shapes need to be fused, ultrasonic machines offer an excellent approach. But what exactly are they, and how do they work?

Ultrasonic Machines in a Nutshell

What are ultrasonic machines? In a nutshell, they facilitate welding on plastics and metal through the use of high-frequency vibrations. These vibrations cause the material being welded to soften, from where pressure can be applied to fuse them together.

It offers an efficient and accurate approach to welding soft materials, particularly when odd dimensions make it difficult for other approaches to welding to achieve accurate results.

So let’s take a look at how it works:

How do they Work?

Plastic or metal parts are held together in the ultrasonic machine between a metal nest and a horn. Through this, pressure is applied to the material.

The horn then produces high-frequency vibrations which are substantial enough to cause the material to heat up and soften. Since there is pressure placed on the material through the nest, as it heats up, the pressure applied causes the parts to fuse together.

Once the objects have been fused together, the vibration stops, causing the material to cool and solidify.

This results in a completed weld and a solid object that cannot be separated afterwards.

Contact M.E.E to Learn More

If you would like to learn more about sourcing specialised ultrasonic machines for your welding needs, be sure to get into contact with a representative from M.E.E today, or visit our website for additional details.

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