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Dukane, the global leader in advanced ultrasonic welding technology, has partnered with one of the world’s largest pharmaceutical manufacturers to improve the production of high-volume injectable drug delivery devices, including applications for GLP-1 therapies and insulin delivery.
As demand for injectable therapies continues to grow, manufacturers face increasing pressure to deliver dependable, high-quality components at scale. In this case, the customer had an established production process but encountered challenges in achieving the weld consistency and process control required for reliable, high-volume manufacturing.
The issue was most evident in the button assembly of the injector pens, where plastic components were welded to an internal post. Using 20 kHz pneumatic welding systems, the manufacturer experienced inconsistent weld strength. In some cases, the welds were insufficient, creating a risk of product failure during use.
In medical applications, that level of variability is not acceptable. The manufacturer needed a solution that could increase weld performance and strength without requiring changes to the part design, materials, or cycle time. Maintaining these parameters was critical to avoid disruption to existing production and validation processes.
Dukane became involved during the exploratory phase, working closely with the customer to assess the application and identify opportunities for improvement. Through testing and collaborative engineering efforts, Dukane introduced the servo-driven ultrasonic welding approach using their Infinity™ platform with patented Melt-Match® technology.
With more than a decade of experience in servo-driven ultrasonic welding, Dukane was uniquely positioned to deliver a level of process control not available with conventional welding methods. The combination of servo technology and Melt-Match® allowed for more precise management of energy delivery during the weld process, resulting in enhanced weld strength and overall performance.
Compared to the pneumatic systems that were being phased out, the servo-driven system provided greater control over weld force, speed, and energy delivery, enabling stronger and more reliable welds across multiple production lines.
The transition to a 30 kHz ultrasonic system further enhanced performance by enabling deeper weld energy penetration. The higher frequency allowed energy to be focused more precisely at the joint, improving weld strength and repeatability.
In addition to increased weld strength, the system provided enhanced process visibility. Quality control personnel were able to monitor and record data for each weld cycle, improving traceability and allowing for better process control over time.
The result was a significant improvement in consistency and overall process capability, enabling the manufacturer to move forward with confidence in high-volume production. Today, the process supports the production of millions of injector pens used in critical medical applications worldwide.
To learn more about how Dukane’s advanced servo ultrasonic technology can support your manufacturing process, please contact Dukane.