Ultrasonic welding utilizes high frequency, vertical motion to produce heat and the flow of thermoplastic material at the interface of mated parts. Pressure is maintained after the delivery of energy is stopped to allow re-solidification of interwoven plastic at the joint, securing the parts with a homogeneous or mechanical bond. This process offers an environmentally friendly means of assembly as opposed to conventional adhesives or mechanical fasteners.
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Consumer products, automotive components, medical devices and most all industries utilize Ultrasonics. Metal inserts may be secured in plastic and dissimilar materials can often be bonded with proper tooling design. ToolTex specializes in toepad welding applications and has worked on several automotive applications. See below for more information on toepad welding.
Even the simplest, timer based ultrasonic press is capable of reasonable precision, and stepping up to energy based units, linear encoded or servo driven presses greatly enhance highly repeatable assembly with tolerances of less than one one-thousandth (0.001″) of an inch.
Joint Design & Tooling
Tooltex will guide you through the process of determining the best joint type and geometry for the material and application you have developed…before you’ve cut the injection mold. We began as specialists in Ultrasonic Welding and are long-time partners with the founder of this technology, Sonics & Materials. If your product can be Ultrasonically welded, we can develop the tooling you will need for robust and reliable processing.
Most ultrasonic welds are completed in seconds, which eliminates the need for costly or consumables…no “screws or glue”. We have customers with Ultrasonic equipment and tooling that have been in service for over a decade with millions of trouble-free cycles. From bench-top welders to fully integrated, multi-thruster arrays, sequencing power from a single supply, Tooltex designs and fabricates the best solution for your processing demands.
ToolTex has spent years perfecting the toepad welding process using ultrasonics. Through the use of 15kHz ultrasonics, we are able to achieve superior strength when compared to other methods, and the finish is unlike any other.
Because our process forms the design and texture of the toepad during welding, there is no longer a need to have pre-molded parts; only 1 – 1.5mm thick vinyl cutouts are needed.