Ever since ultrasonic welding began in the early 1940s, its usage in various applications hasmultiplied. As new materials have cropped up in the market, its industrial practices have increased. It has evolved from the simple high-wave frequency sound to bond materials in the solid state to melt. Bench-top models have valve controls, line voltage, linear encoders and functions for better results.  

For example, ultrasonic plastic welding is a routine process in the automobile industry. One component rules the rest-Sonotrode in the transducer assembly along with the converter and booster. Why is it the key-driver for many operations?

RTUL group clearly understands its importance in design and correct fitness. With nearly 40 years of experience, we are ready to meet the different requirements of the automobile sector. Our product range of ultrasonic machine types meet welding necessities. Get to know about our design basics to weld tricky plastic parts.

Sonotrode’s role in the automobile industry

An ultrasonic machine used in joining plastic parts require the highest quality of weld. A vehicle has many parts to be integrated in a tight formation. High automotive components should also look visually appealing and within the right dimensions. Economic solutions for bonding them also require process optimization.

While thinking of the right design for ultrasonic welding, there are various factors to be considered. The process is convenient for various automotive applications ranging from interiors like joining consoles, dashboards, engine compartments, filters, acoustic foams, and lighting.

RTUL Group team makes the design strong enough so that the ultrasonic machine works with minimal heat-up time. This efficiency reduces the energy consumption for long operations.

The sonotrode is also called the weld horn. Its shape should fit the shape of the assembly part. If it does not fit well, the vibration is not effective. In the automobile industry, many different parts are joined or bonded and they have asymmetrical shapes. Different materials like plastic, leather, and foam are also combined. When plastic parts are welded with other materials, they should be durable.

Our team understands that technology may have its limits also. Hence, the optimal sonotrode design helps clients to yield better results.

How do we meet the challenges?

For example, hot welding produces challenges of uneven temperature distribution. The colder sections may not uniformly bond. When vibration is used the joint area should have the right amount of plastic for welding. Sonotrodes also assumes importance for joining engine parts. Our team efforts ensure that the ultrasonic machine we offer has strong mounts for the horn section. They match the parts to be joined and support the spots where welding is critical.

We have done several customized projects for our clients. Our solutions are based on the specific requirements during the production of the equipment. Our welding systems are preferred for the integration of customized weld parts.  

Visit the RTUL Group’s website to learn more about ultrasonic plastic welding devices. Our aim is always to assist and support our clients to get a finished product. We provide solutions for bonding complex materials like plastics and non-ferrous metals.