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iQ Servo Ultrasonic Welding

Patented Melt-Match®

Melt-Match® precisely matches the velocity of the ultrasonic stack with the melt flow velocity of the plastic material ensuring optimum molecular intermingling.

100% Electric/Servo

All-electric true servo technology eliminates the variability associated with pneumatic press components and provides unprecedented control to ultrasonic welding process.

0.5 ms Sample Rate

Fast collection of data points during the weld improves repeatability and enhances reliability of the welding output and programmed quality controls.

Precise Calibration

Displays all Weld parameters, limits and graphs from the weld cycle. 100% digital all-electric control simplifies the calibration and validation process.


“We were looking for increased accuracy and repeatability in our welding process. Dukane’s iQ Servo was easily able to achieve our requirements and the simple iQ Explorer II application software was intuitive. This made process development and optimization very efficient and straight forward.”

–R&D Engineer at Surgical IOL at Alcon Laboratories

“A small plastic stem was being damaged during welding and we were unable to optimize the weld settings on our pneumatic sonic welder to alleviate this issue. iQ Servo Ultrasonic Welder with patented Melt-Match® technology eliminated the problem. The data collected during the servo process optimization had a tighter standard deviation and a significantly higher process capability (Cpk). The ability to weld at a constant velocity and/or program a custom weld velocity profile greatly improved the welding process. The Melt-Match® feature provided stronger welds.”

–Process Engineer Bard Access Systems, Inc.



Key Features

  • Top-of-stroke limit switch for automation application
  • Patented Melt-Match® Technology
  • Linear distance encoder with 1 μm resolution
  • Patented Melt-Detect™ Technology
  • Programmable trigger force .1 lb resolution (1 lb 20 kHz version) Ideal for precise delicate assemblies
  • Industry leading 0.5 ms acquisition rate
  • Programmable home position for reduced cycle time and setup optimization
  • Superior Data Acquisition
  • FDA Compliance with features like multi-level password protection, process change audit history and documentation (21 CFR part 11)
  • Simple calibration procedure – no pneumatic components to adjust
  • No operator accessible adjustment knobs or controls ensures validated process remains unchanged. All mechanical changes require a specific tool.
  • Only one device required for calibration (Trigger Force Sensor)
  • Dynamic Servo Motion Control
  • All other parameters validated (no adjustment – functional tests only – distance, time & velocity)
  • Linear servo actuator with integral roller screw mechanism
  • 5” (127mm) stroke 20 kHz, 3.5” (89mm) 30/40/50 kHz with a teachable software travel limit