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PPE Face Mask Construction with Ultrasonic Bonding Technology

Why Ultrasonic?

  • Get clean process and seam without any consumables or additives in the seam
  • Achieve molecular bonds at the seam no holes from sewing, or weak strands 
  • Assemble variety of non woven materials including SMS, Polypropelene Spun, SSS, SMMS
  • Eliminate the cost of adhesive and the glue delivery system and get upto 5X faster cycle rate
  • Reduce maintenance downtime by eliminating glue applicator and spray nozzles from the process
  • With a wide array of ultrasonic bonding technologies every part of a face mask can be attached using ultrasonic joining

Ultrasonic Bonding N95 Masks

N95 Thermoformed Masks

  • Ultrasonic bonding of Perimeter
  • Ultrasonic bonding filter media to shell
  • Ultrasonic bonding of straps to mask

Manual Folding N95 Mask

  • Die cut Nonwoven material to shape
  • Weld Outline with large block style horn
  • Weld Ear Loops with Hand Probe
  • Fold Mask over and weld final nose seam

Clean and Strong Ultrasonic Cut & Seal For Respirator Filters

Single Step Ultrasonic Cut & Seal with Servo Control

  • Single step cut and seal process for various nonwoven materials and filter media
  • Ultrasonic eliminates material fraying and provides clean finish
  • Reduces Tooling Damages with servo controlled process

Multilayer Surgical Mask Construction


Automation Ready Ultrasonic Generators

  • Capable of plunge and continuous bonding
  • Multiple Welding Modes designed to meet various requirement of your PPE Mask applications
  • Industry 4.0 ready power supply with patented Trigger by Power™ feature to ensure consistent welds
  • Wide range of models with Power Levels of 600 & 1200 watts & frequencies of 20, 30, 35 & 40 kHz
  • Quick & Easy Integration into electrical panels with easy access to connectors and cables
  • Turnkey PLC and HMI (iQLinQ™) code is provided for easy integration/time saving
Learn About Dukane's Ultrasonic Generators

Optimizing Horn Design to Improve the performance

  • Finite Element Analysis is used to simulate a horn’s performance before it is manufactured
  •  Based on the analysis tooling engineers make changes in the design that helps in reducing stress and amplitude variation
  • Optimizes the performance and provides the best welding results

Learn About Horn Performance

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