Automotive Applications - Dukane Ultrasonic Assembly Equipment

Automotive Welding Solutions

Efficient Process Control, Robust Design, 24/7 Welding Service & Support for automotive industry

Dukane is a global provider of plastic welding equipment designed to provide professionals in the automotive industry robust, effective and controllable welding equipment and solutions. Our plastic welding solutions are designed to help automotive parts manufacturers meet stringent CAFE regulations and satisfy their customer’s expectations. We work with you from concept to launch. Beginning with designing your auto parts according to your criteria. Continuing to provide low cost, lean manufacturing solutions and working with you until you meet your customer’s requirements into production.

  • Classic Plastic Welding Applications for Automotive Industry
  • Recent Success with new auto applications
  • Automotive Technical Centers
  • Classic Plastic Welding Applications for Automotive Industry

    Tail Lamps

    Automotive tail lamps utilize Hot plate, Vibration, Ultrasonic and Laser Welding in their assembly methods. The new tail lamps have become more complex and welding the components together is still the industry standard.

    Intake Manifolds

    Intake manifolds are two to five injection-molded plastic pieces that are typically joined through vibration welding. Hermetic seals with high burst strength are required for this automotive application.

    Glove Boxes

    Glove Boxes are more than a place to put the car manual. It is a safety device that absorbs the impact of the knees during a head on collision and transfers the load to the Energy Absorption brackets. They are usually joined through vibration welding but some auto professionals prefer to use hot plate welders. In most cases, latch mechanisms are in place during welding.

    Rear Spoilers

    Rear spoilers are a unique auto industry welding application. Sometimes they are ultrasonically welded. Most of the time vibration welding techniques are used after the part is painted in 90 gloss body paint. No marking of painted surface is seen when in production.

    Instrument Clusters

    Instrument clusters have long been vibration welded. The clear acrylic is welded to the ABS mask. No marking occurs to this soft lens. Today there are lots of new trim rings (typically chrome plated) that are ultrasonically staked to the IP components.

    Door Trim Panels

    Ultrasonic heat staking is the industry standard for interior auto door trim panels. The use of spot welding can also save money in material and mold costs. Sound deadeners and other automotive components like EA bolsters can also be attached using ultrasonics.


    Automotive consoles have been assembled in many different ways. The use of Ultrasonics, Heat Staking, Vibration and Hot plate welders have been used to assemble a large portion of these consoles.

    Carbon Canisters

    The automotive carbon canister made of nylon is the reason we have the vibration welding process today. When they failed using ultrasonic welding, vibration welding was developed to make these products. It is a simple and highly reliable process. At times, ports are spin welded to the outside of the canister. The use of ultrasonics is used to weld filter materials to the inside of the canister.

    Recent Welding Successes in the Automotive Industry

    Tail Lamps

    The current Ford Mustang tail lamps utilize ultrasonics to spot weld the ABS chrome strips to the tail lamp lens. While a very challenging welding application, it is one of the many possibilities for Dukane's welders and equipment. Simple chrome strips can be welded with no issue and save big dollars compared to adhesive solutions.

    Charge Cord Assemblies

    Electronic vehicles have hit the road and are making an impact in the auto industry. The charge cord assemblies used in these vehicles present a big opportunity for ultrasonics and vibration welders in their assembly. The tamper evident process of either of these applications also provides structures that a vehicle can drive over without destroying the assembly

    Partner in your success

    Dukane provides unparalleled service and support to make your medical, hospital and surgical equipment manufacturing a success. We work with you from application concept to finished part, and we will continue to provide support after you are in full production. Our team of medical equipment manufacturing industry experts will assist you from beginning to end. We provide assistance with assembly method/equipment selection, joint design, feasibility studies, and welding system validation and calibration.