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Ultrasonic Welding Automation

Genesis Automation is your one-stop headquarters for high-quality, reliable automation solutions. We will help design a custom assembly system that integrates ultrasonic welding equipment to meet your company's requirements.

Get in Touch To Discuss Your Requirements Today.

What Is Ultrasonic Welding?

Ultrasonic technology isn't new — manufacturers have been using it to join thermoplastics or connect them with other materials for over 70 years. This indirect heat welding process uses ultrasonic waves, which are sound waves generated at a frequency above the limits of human hearing.

The process converts high-frequency electronic vibrations into ultrasonic waves that heat and weld the two workpieces. The heating occurs at the boundary surfaces of the parts without impacting the adjoining areas, reducing the risk of damage. A permanent bond forms as the welded area cools, creating a clean and stable joint seam.

Ultrasonic welding has many industrial applications:

Bonding smaller parts and components in electronic and communication devices
Fabricating automotive parts, such as headlamps, fuel filters, seat belt locks, fluid vessels and electronic key fobs
Manufacturing medical parts like catheters, filters and masks
Producing various packaging items, including blister packs, containers, tubes, carton spouts and pouches
Joining wire terminals, brush plates and brush wires

Ultrasonic welding offers numerous benefits:

Speed: The shorter process times enable you to complete your projects on schedule.

2. Less damage: The use of cold welding tools protects the workpieces from heat damage.

3. Safety: Workers won't need to worry about injuries from hot machine parts.

4. Versatility: Ultrasonic welding works with various thermoplastic materials.

Types of Ultrasonic Welding?

The two ultrasonic welding types include:

Plastic ultrasonic welding: This plastic-to-plastic welding process works with various thermoplastics and other materials like polycarbonate/ABS, low- and high-density polyethylene, acrylic and cellulose acetate. You can also use it to join fabrics to plastic.

Ultrasonic metal welding: Metal-to-metal ultrasonic welding is a solid-state process that creates metallurgic bonds via friction. While this method can work with most metals, it typically involves various alloys of aluminum, copper, magnesium, silver and gold.

Custom Project Engineering for Your Ultrasonic Welding Needs

At Genesis Automation, we do whatever it takes to deliver a result that meets our customers' expectations, including developing and implementing custom processes:

Custom assembly solutions: Each system is a unique and complete solution to your assembly and manufacturing process needs. Our services include part feeding and handling, forming, assembling and bonding processes, and ultrasonic weld testing.
Laser welding expertise: We offer more than 20 years of experience with ultrasonic welding applications, serving a wide variety of industries. We understand how to integrate our advanced design concepts, processes and plastic assembly technologies.

Get in Touch With Genesis Automation

Could integrating ultrasonic welding into your company's assembly systems add value to your manufacturing processes? Would you like more information about the technology and its numerous benefits?

At Genesis Automation, we consider ourselves an extension of our customers' team. We can answer all your questions and provide timely, reliable support throughout the process. Call us at 630-587-0444, or submit our online contact form to request more information today.