Why am I getting inconsistent parts?

QUESTION: I’m getting inconsistent parts even though I’m following the same parameters. Why? ANSWER: You need to look at all elements of the project in order to pinpoint the problem. We suggest looking at the molded parts for warpage, heat sinks and cavity-to-cavity variations. Look at the joint design to make sure you have the… Continue Reading Why am I getting inconsistent parts?

Dukane at NPE 2012 in Orlando, FL

NPE 2012 is next week. This will be the first year that NPE will be held in Orlando Florida. The show claims there will be 55,000 attendees which is up by 10% over 2009. They have posted that there are 1,826 exhibitors. The number of foreign registrants this year is 26% compared to 16% in 2009.… Continue Reading Dukane at NPE 2012 in Orlando, FL

What Amplitude is needed to weld my plastic components?

What exactly is “Amplitude” and why is it important?  Amplitude is the peak-to-peak movement, or expansion/contraction, of an ultrasonic tool stack.  Each component can multiply the amplitude that comes from the transducer, the amount of increase or decrease is called “Gain”.  The total gain of the stack components determines the final amplitude at the working… Continue Reading What Amplitude is needed to weld my plastic components?

Understanding Ultrasonic Stack

It is essential that the mating faces between an ultrasonic transducer/booster and a booster/horn be flat and parallel. If any air gaps remain, there will be a resultant loss in power output and efficiency. Coupling may be so poor that it might prevent the starting of an ultrasonic stack. The condition of excessive crowning, or… Continue Reading Understanding Ultrasonic Stack

How Tight is Tight Enough?

It is important to assemble and tighten your ultrasonic tooling stack to a proper torque. Just assembling the tooling stack as tight as possible could be detrimental to the tooling stack components. For example: the threads on an aluminum booster or aluminum horn can be stripped out due to over-tightening. Conversely, not using enough torque… Continue Reading How Tight is Tight Enough?

How does your Ultrasonic Probe/Stack work?

Ultrasonic Probe Plastic welding is the most common application of ultrasonic assembly. To perform ultrasonic plastic welding, a vibrating tip is brought into contact with one of the work pieces as shown in Figure 1–1. Pressure is applied and ultrasonic energy travels through the material, increasing the kinetic energy (or heat) at the contact point… Continue Reading How does your Ultrasonic Probe/Stack work?