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?

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?

Novel Combination Locking Cap for Prescription Drugs

New plastic locking cap uses Dukane’s ultrasonic welding system for speed, accuracy, and precision manufacturing Cap-N-Lock LLC, Lincoln, Calif., has developed the industry’s first combination locking cap offering maximum security against unauthorized use of prescription medications. The plastic locking cap is claimed to be the safest child-proof cap, provides maximum protection against teen prescription use, and… Continue Reading Novel Combination Locking Cap for Prescription Drugs

Multiple Slit Applications – Narrow Gauge or Standard Slitting?

This question can be answered different ways but let’s discuss the difference from the two methods of Ultrasonic Narrow Gauge Slitting and Standard Ultrasonic Slitting. Narrow Gauge Slitting is when a series of Individual Slitting Modules are positioned under a Long Ultrasonic Bar Horn usually about 9” in length. Depending on the centerlines and number… Continue Reading Multiple Slit Applications – Narrow Gauge or Standard Slitting?

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

When should I consider using ultrasonics to cut my food product?

Ultrasonic food processing involves a vibrating knife producing a nearly frictionless surface to which food products do not stick nor deform. Here are some things to consider when deciding if ultrasonic cutting is the right process for your application. Is your product sticky and causing excessive downtime for blade cleaning? Does your current cutting process… Continue Reading When should I consider using ultrasonics to cut my food product?

Ultrasonic Welding Effects on Hearing

In air, sound is usually described as variations of pressure above and below atmospheric pressure. These fluctuations, commonly called sound pressure, develop when a vibrating surface forms areas of high and low pressure, which transmit from the source as sound. Although noise-induced hearing loss is one of the most common occupational illnesses, it is often… Continue Reading Ultrasonic Welding Effects on Hearing

Composite Ultrasonic Horns

A composite horn is actually a half-wave “coupler” horn with two or more half-wave, tuned horns attached to it. This technology was patented by Dukane in 1973. Because composite ultrasonic horn designs can often eliminate the need to invest in additional assembly systems, they reduce equipment costs and minimize production time for customers. Composite ultrasonic… Continue Reading Composite Ultrasonic Horns

What Happened to Your Ultrasonic Weld Quality?

The most important factor in troubleshooting problems in ultrasonic welding is understanding the fundamentals of the process. With this basic knowledge, most problems can be easily diagnosed and resolved. Even so, sometimes your time-tested weld recipe may suddenly fail for no discernible reason. Perhaps your ultrasonic welder has been running the same application for months,… Continue Reading What Happened to Your Ultrasonic Weld Quality?

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?