Diabetes Care

Products
- Ultrasonic Products
  - Ultrasonic Welders
    - Infinity™ with Melt-Match®
    - P220 Ultrasonic Welder
  - Ultrasonic Film & Fabric Processing
  - Ultrasonic Cutting Solutions
  - Automation Ready Ultrasonic Welding
  - Custom Ultrasonic Welders
  - Ultrasonic Hand Probe Systems
    - iQ Series Hand Held System
  - Proprietary User Interface/Software
    - iQ Explorer for Select Ultrasonic Welders
  - Additional Ultrasonic Products
  - Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic WorldChoose between Dukane's Infinity with Melt-Match technology or the P220 Ultrasonic Welder. Produce fast and consistently by programming ultrasonic stack velocity, force, and position throughout the entire welding process for stronger welds.Rugged Construction using the highest quality components provides superior performance, precision, and reliability. Compact, Single-Rail Linear Ball Slide Assembly System offers accurate positioning, stable movement, and friction-free travel.Ultrasonic Fabric & film processing is the bonding, slitting, or sealing of fabrics and films containing thermoplastic material(s).i220 Bag Sealer provides a hermetic seal to thermoplastic valves on bags used for packaging powders, food, and hygroscopic products, which prevents product loss, moisture intrusion or pest infiltration.Ultrasonic provides clean and strong bonds by eliminating consumables or additives in the seam. Achieve molecular bonds at the seam no holes from sewing, or weak strands.Produce fast and consistently by programming ultrasonic stack velocity, force, and position throughout the entire welding process for stronger welds.iQ Servo Controlled Ultrasonic welding system provides single step cut and seal process to various film, fabric, and nonwoven materials. Ultrasonic eliminates material fraying and provides clean finish.Ultrasonic cutting solutions for precise, clean, and efficient cuts in food processing, packaging, and industrial applications. Enhance productivity and sustainability with our advanced cutting technologyUltrasonic Cuts are cleaner than conventional cutters with minimal debris Ideal for cutting rubber, composite aerospace materials such carbon fiber, nomex and various honeycombs.Highly precise ultrasonic vibrations create clean and neat cuts without causing fraying or deformation of the rubber edges, allowing for intricate and accurate cuts, particularly when dealing with complex shapes or intricate patterns in rubber materials. Dukane’s ultrasonic food cutting systems use food-grade blades to deliver clean, precise cuts in cheese, confections, and more. Boost hygiene and reduce waste today.Reduce cycle time and get a custom-designed compact work cell with the patented Multi-Probe Control feature of our ultrasonic generators. Multiple probes are controlled with one ultrasonic generator, but each ultrasonic probe has its own unique weld recipe.Have more flexibility in your welding process with multiple modes. This includes Weld by Distance, Energy, Peak Power, Time, and Continuous Mode with process limits for all the parameters.Quick and Easy integration in automation systems with Ultrasonic Generator. Seamlessly fits your control panel either vertically or horizontally and an intelligent cable management setup ensures a clean look and finishQuick and economical integration for automation systems. Seamlessly fits your control panel either vertically or horizontally. Integrated MPC(Multi-Point Controller) minimizes cabling to ensure a clean look and finish.Trigger by Power patented feature provides ability to accurately start the weld process once a programmed force is achieved. Coupled with weld by energy, this unit delivers the highest level of process repeatability of any probe system available today.The Multi-Point Control unit is designed for assembly systems where one ultrasonic power supply is sequenced to several ultrasonic probes. Our unique Control and Process Monitoring Profile is available for each individual probe when coupled with a Dukane iQ Series ultrasonic generator.Let Dukane help you determine which ultrasonic welder is right for your application. Machine is constructed from tubular steel frame and 1 inch thick steel Blanchard ground top. Fork truck tubes and robust guarded castors in the base makes it easy to move and placeAutomation for manufacturers today require more flexibility and multipurpose machines to outpace their competition. Robot based work cells provide this flexibility and control for ultrasonic welding applications.Ultrasonic Generators with patented MPC controls multiple ultrasonic probes, minimizes capital investment, and simplifies machine programming.Rotary work cells are an economical solution for increasing throughput for small to medium sized assemblies . Rotary systems can be manual or semiautomatic in operation and are available in indexes of 2, 4, 8, 12 stations to name just a few.The HP and PG series hand probes feature an ergonomic soft grip design with attachments for use on counterbalance devices.The hand held welder has a soft grip and lightweight operator friendly hand probes. Lightweight unit with integrated handle makes the unit portable for plant mobility. Audible end of cycle notification alerts operator cycle is complete.Automation ready ultrasonic welding with proprietary iQLinQ™ communication protocol to interface ultrasonic generators with automated systems.Rotary horns provide higher, continuous power delivery. More power means faster, more consistent sealing. Focused energy and the “flywheel effect” of the rotary system allow for greatly increased sealing speeds and highly consistent seal integrity.Ultrasonic food processing involves a vibrating knife (guillotine) producing a nearly frictionless surface that minimizes buildup on the blade surface.Titanium is generally the preferred material for horns because it provides good fatigue strength, excellent acoustic properties and good surface hardness.iQ EZ Stapler is a small compact module designed to weld blister/clamshell packages. The system is activated by a foot-switch to free up the use of the operator’s hands to quickly and easily weld any size of package.Talk with an expert, contact us today. We're always ready to help.
- Laser Plastic Welding System
- Vibration Welding
  - 5000 Series
  - VW 6000 Series with Melt-Match®
  - Dukane Vibration Welding systems provide clean, fast, well-suited for joining large parts, and the ability to produce high-quality joints.VW 5000 Series Vibration Welders Ultrasonic Welders set the industry benchmark when it comes to quality, standard and precision in plastic welding.This small machine packs all the features used in Dukane’s larger vibration welders into a smaller footprint when factory floor space is limited and the finished part size is 400mm x 500mm or less.Patented digital frequency drive delivers more power efficiency, reliability and flexibility for unique applications. Service spares, and drive upgrades are provided directly from Dukane eliminating dependency on third party manufacturers.Provides real time graphing of amplitude, pressure, and collapse distance, which gives users additional control to monitor, evaluate and troubleshoot their vibration welding process. Built in logical control eliminates the need of PLC programming expert for changing simple standard machine logic.Dukane’s WIDE part size machine was developed to weld wider and shorter parts such as intake manifolds and other parts sized up to 950 mm x 510 mm. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source.Well suited to assemble large parts (1550mm x 550mm) with sturdy mechanical features. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source. Robust frame with numerous cross members to support dovetail slide system for table.Dukane’s WIDE part size machine was developed to weld wider and shorter parts such as intake manifolds and other parts sized up to 950 mm x 510 mm. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source.Provides the largest welding table in the industry with the smallest footprint, 25% smaller than current models.Talk with an expert, contact us today. We're always ready to help.
- Spin Welders
  - Servo Weld ™ Plus Spin Welder
  - Spin WeldingServo Weld Plus Spin Welder electric press system uses two servo motors for precise control & accuracy in welding plastic assemblies w/circular weld joints.Talk with an expert, contact us today. We're always ready to help.
- Particulate Free Welding
  - Hot Gas Welding
  - Infrared Welding - TH3
  - Rotary Infrared Welding
  - Two-Phase Thermoforming
  - Eliminate particulate from your welding process and produce cleaner, stronger plastic parts with better aesthetics with latest welding technologies.Our patented procedure for particle-free and oxidation-free welding.TH3-Thermal Hybrid is one platform designed to offer Infrared, Hot Plate & Hot Gas Welding solutions. Users can buy one system and quickly configure the TH3 to weld using one of the three welding processes (Infrared, Hot Gas and Hot Plate) by quickly changing between different tools and components in the system.Dukane’s rotary infrared welding system is tailored for assemblies falling within a footprint of 200mm x 250mm or less, requiring a faster cycle rate than cannot be provided by conventional hot plate or infrared welders. This unique machine provides a non-contact infrared welding solution that is capable of producing welded assemblies as rapidly as every 8 seconds as compared to conventional IR welding machines that run at a rate of 30-40 seconds per cycle.The Two-Phase Thermoforming can be used for all thermoplastic materials; therefore, plastic-plastic and plastic-metal can be assembled without any problems.Talk with an expert, contact us today. We're always ready to help.
- Hot Plate Welders
  - Hot Plate Welder - TH3
  - After the plastic interfaces have melted, the parts are brought together to form a molecular, permanent, and often hermetic bond. TH3 hybrid platform with rapid changeover between Hot Plate, Hot Gas, and Infrared tools and components delivers cost savings for future programs. Talk with an expert, contact us today. We're always ready to help.
- Rotary Ultrasonic Solutions
  - Rotary Ultrasonic Solutions for Packaging
  - Rotary Ultrasonic Sealing for Nonwovens
  - Dukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials.Dukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials.Soniseal™ WD bonders have full wash-down capability and can remain on the machine during cleaning. No bagging necessary!Rotary horns provide higher, continuous power delivery. More power means faster, more consistent sealing. The Sonisolution™ RS Series of rotary ultrasonic sonotrode assemblies offers many benefits for your customers. Some of those benefits include the capability of reducing raw materials, increasing process speeds, improving product quality, and decreasing equipment maintenance. Aurizon® patented technology allows those with the technical knowledge to integrate high power ultrasonic capability into their machine designs.The Soniseal™ 40 Series uses patented Aurizon® rotary ultrasonic technology to enable new capabilities in packaging applications. The Series consists of pre-engineered systems that deliver performance and savings by increasing productivity and reducing costs when implemented. Dukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials. A Dukane patented process where elastic strands are entrapped between the two layers of Nonwoven materials using ultrasonic energy. Directly attach elastic strands to the substrate web and avoid all costly adhesive materials and complex adhesive delivery systems.We have solutions for seaming materials together utilizing our proven and patented technology to the attachment of tabs and other articles without the need for glue.Ultrasonic Lamination systems use a low-density anvil pattern to tack materials together while leaving the majority of the web open for other functional attributes (e.g. absorbency).Ultrasonic Cut and Seal technology offers a variety of solutions for a broad range of end-use applications.Talk with an expert, contact us today. We're always ready to help.
Markets We Serve
- Automotive
  - Ultrasonic Tire Cutting
  - Dukane offers the widest range of plastic welding processes for automotive part manufacturers. Whether you are designing an exquisite exterior tail light, under the hood plastic assemblies, or interior components we have the right plastic joining solution for the project.Talk with an expert, contact us today. We're always ready to help.
- Medical
  - Diabetes Care
  - Critical Hospital Care
  - Advanced Home Care
  - Wearables & PPE
  - Discover advanced ultrasonic welding and laser welding solutions for medical device manufacturing. Our servo-controlled ultrasonic plastic welding and precision laser welding ensure high-quality, reliable medical devices.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Talk with an expert, contact us today. We're always ready to help.
- Electronics
- Non-woven & Hygiene
  - Full Panel Elastic With Ultrasonic Bonding
  - Face Mask Construction
  - Disposable Gown Construction
  - Ultrasonics provides the cleanest, fastest, and most efficient method for bonding non-woven materials. Rotary bonding, plunge bonding, single step cut and seal of non-woven materials or...Our Adhesive Free Elastic Entrapment solution consists of a high-speed ultrasonic bonding system to attach elastic strands to nonwovens without adhesive. Elastic strands and nonwoven substrates are bonded as they pass through a high-speed rotary ultrasonic drum and anvil.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.Get clean process and seam without any consumables or additives in the seam. Reduce maintenance downtime by eliminating glue applicator and spray nozzles from the process. Eliminate raw material wastage at the start and stop of the cycle caused by idle heat bars in heat sealing.Talk with an expert, contact us today. We're always ready to help.
- Food
- Packaging
  - SynQro Spout Sealing Module
  - Whether you're looking to incorporate highly accurate and consistent ultrasonic welding stations into a high-speed automated line or a cost effective packaging solution for a low volume assembly, Dukane has a product to meet your needs.Patented SynQro technology enables dialogue between two ultrasonic generators to drive energy through two sonotrodes instead of one sonotrode and anvil.Talk with an expert, contact us today. We're always ready to help.
- Automation
- Ultrasonic Cutting
  - Ultrasonic Tire Cutting
  - Dukane’s ultrasonic cutting systems are designed for cutting thermoplastic films, rubber, and woven and non-woven fabrics. Utilizing the latest in cutting blade technology Dukane cutting systems are ideal for cutting...Talk with an expert, contact us today. We're always ready to help.
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- FAQs
- Our Processes
  - Ultrasonic Plastic Welding
  - Vibration Welding
  - Laser Welding
  - Spin Welding
  - Infrared Welding
  - Hot Plate Welding
  - Ultrasonic Food Cutting
  - Ultrasonic Film & Fabric Processing
  - The plastic welding process creates a molecular bond between two compatible thermoplastics. Three main steps to any weld: pressing, heating, and cooling.Ultrasonic thermoplastic welding process is the joining or reforming of materials through the use of heat generated from high-frequency mechanical motion.Compared to ultrasonic welding, vibration welders operate at much lower frequencies, higher amplitudes and much greater clamping force.Laser welding is a non-contact joining method that uses a laser beam to melt the plastic in the joint area by delivering a controlled amount of energy to a precise location. Precision in controlling the heat input is based on the ease of adjusting the laser beam size and the range of methods available for positioning the beam. Most thermoplastics can be welded using a proper laser source and appropriate joint design.This process works through rotational motion of one part relative to the other. This results in surface friction that leads to heat generation and the formation of a melt layer at the joint. Spin welding typically has weld times from one-half to five seconds. Dukane’s spin welders can handle parts from approximately one-half inch (12 mm) diameter using high speed motors up to nine inches (225 mm) diameter using high torque motors.Another non-contact welding method is infrared welding that uses radiation to transfer heat to the plastic parts. It follows the same fundamental steps as hot plate welding. Two different approaches to infrared welding have emerged. One of the systems uses an electrically heated metal plate which, in some cases, is coated with a ceramic. In the other system, the standard heater plate is replaced with infrared emitters clamped and spring-loaded on either side of a movable platen.Hot plate welding process uses conduction, convection and/or radiation from an actual heated platen to melt the fraying surfaces of the plastic parts.Ultrasonic food processing involves a vibrating knife producing a nearly frictionless surface which does not deform food products and to which they do not stick. The surface cleanly cuts or slits products including fillers such as nuts, raisins, dried fruit or chocolate morsels without displacement or plowing.Typical fabric & film installations are multiheaded systems that take advantage of Dukane's narrow profile thrusters’ close center-to-center positioning.Talk with an expert, contact us today. We're always ready to help.
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Overview

Dukane’s advanced plastic welding technologies ensures precision, consistency, and compliance in diabetes care product manufacturing. It enables high-quality, hermetically sealed welds for insulin pens, glucose monitors, glucose pump housings and infusion sets.

Continuous Glucose Monitor - Diabetes Care

Continuous glucose monitors (CGMs) are diabetic care devices for monitoring blood glucose levels continually. They typically comprise of an electrode placed under the skin and a transmitter to regularly send blood sugar level readings to a separate receiver display. CGMs are alternate devices to the traditional periodic glucose monitoring by drawing blood from a finger.

Typical Materials

PC
ABS
PC/ABS
PE
PP

Typical Joint Designs

Tongue & Groove Round Energy Director (Servo)
Tongue & Groove Standard Energy Director
Tongue & Groove Shear

Bonding Process

Servo Ultrasonic Welding – Typical

Molding Considerations

Materials are considered ultrasonically compatible when their melt temperatures are within 30°F and melt flow indices are within 10% of each other
Avoid re-grind if possible. Less than 25% if required
Avoid mold release agents
Plastic fillers & additives can affect welding output. Contact Dukane for additional information

Typical Optimized U/S Welding Parameters

Sensing Speed	1 mm/s (0.04" in/s)
Melt-Match %	2-5%
Weld Speed	0.25 - 1.5 mm/s (0.01-0.06 in/s)
Weld by Distance	0.13 - 0.5 mm (0.005-0.020 in)
Dynamic Hold	0.01 - 0.05 mm (0.0005-0.0020 in)
Dynamic Hold Speed	3.0 - 4.0 mm/s (0.118-0.157 in/s)
Static Hold	0.5s

Quality Considerations

Advanced cycle/graph data collection and production analysis
Improved weld control with Smart-Stack™ integration and Melt-Match® technology
Integrated FDA 21 CFR-11 security

Geometry Considerations

Horn contact surface & weld joint interface should be on single parallel planes
Near-Field Welding – Joint within 6mm of horn contact surface

High Volume/Automation Requirements

Ethernet IP
Generator and servo controller communication via Ethernet
Industry 4.0. OPC UA connectivity standard
Long actuator life, over 100 MM cycles

Diagnostic Tests

Diagnostic test cartridges are small medical devices designed to receive and analyze patient samples to detect various medical conditions or markers. They can come in a multitude of sizes and designs, with many modern cartridges engineered with the capability to perform multiple tests, such as whole blood analyses for cardiac markers.

Typical Materials

PC
ABS
PP
HIPS
PS

Typical Joint Designs

Tongue & Groove Round Energy Director (Servo)
Step Round Energy Director (Servo)
Tongue & Groove Standard Energy Director
Step Standard Energy Director

Bonding Process

Servo Ultrasonic Welding – Typical

Molding Considerations

Materials are considered ultrasonically compatible when their melt temperatures are within 30°F and melt flow indices are within 10% of each other
Avoid re-grind if possible. Less than 25% if required
Avoid mold release agents
Plastic fillers & additives can affect welding output. Contact Dukane for additional information

Typical Optimized U/S Welding Parameters

Sensing Speed	1 mm/s (0.04" in/s)
Melt-Match %	2-5%
Weld Speed	0.25 - 1.5 mm/s
Weld by Distance	0.13 - 0.5 mm
Dynamic Hold	0.01 - 0.05 mm
Dynamic Hold Speed	3.0 - 4.0 mm/s
Static Hold	0.2 - 0.5s

Quality Considerations

Advanced cycle/graph data collection and production analysis
Improved weld control with Smart-Stack™ integration and Melt-Match® technology
Integrated FDA 21 CFR-11 security

Geometry Considerations

Horn contact surface & weld joint interface should be on single parallel planes
Near-Field Welding – Joint within 6mm of horn contact surface

High Volume/Automation Requirements

Ethernet IP
Generator and servo controller communication via Ethernet
Industry 4.0. OPC UA connectivity standard
Long actuator life, up to 100 MM cycles

Microfluidic Device and Cartridge

Microfluidic devices contain chips with micro-channels and reaction chambers that process and chemically analyze small volumes of fluid (typically blood). These devices offer the advantage of rapid, cost-effective, and precise disease detection and diagnosis.

Typical Materials

PMMA (Acrylic)
SAN
PC
PC/ABS
PS
PP
Tritan

Typical Joint Designs

Tongue & Groove Round Energy Director (Servo)
Tongue & Groove Standard Energy Director
Round Energy Director (Servo – Film to Housing)
Standard Energy Director (Film to Housing)

Bonding Process

Servo Ultrasonic Welding
Laser Welding (color & geometry dependent)

Molding Considerations

Materials are considered ultrasonically compatible when their melt temperatures are within 30°F and melt flow indices are within 10% of each other
Avoid re-grind if possible. Less than 25% if required
Avoid mold release agents
Plastic fillers & additives can affect welding output. Contact Dukane for additional information

Typical Optimized U/S Welding Parameters

Sensing Speed	1 mm/s (0.04" in/s)
Melt-Match %	2-5%
Weld Speed	0.25 - 1.5 mm/s
Weld by Distance	0.13 - 0.5 mm
Dynamic Hold	0.01 - 0.05 mm
Dynamic Hold Speed	3.0 - 4.0 mm/s
Static Hold	0.2 - 0.5s

Quality Considerations

Advanced cycle/graph data collection and production analysis
Improved weld control with Smart-Stack™ integration and Melt-Match® technology
Integrated FDA 21 CFR-11 security

Geometry Considerations

Horn contact surface & weld joint interface should be on single parallel planes
Near-Field Welding – Joint within 0.25" of horn contact surface

High Volume/Automation Requirements

Ethernet IP
Generator and servo controller communication via Ethernet
Industry 4.0. OPC UA connectivity standard
Long actuator life, up to 100 MM cycles

Welding SolutionsPrecise, Accurate and Flexible Welding Solutions

Dukane offers the largest array of plastic joining technologies within the Medical Device Market segment. This allows Dukane the flexibility to GUIDE our partners into the RIGHT joining solution based on the the requirements of their unique medical device assembly. Integrating the right process and the right tool early in the development process ensures a successful long-term program.

Dukane Advanced Welding Solutions for Medical Device Manufacturing:

Infinity X1

Infinity X2

Infinity X3

NRG Laser Welding System

Diabetes Care

Overview

Typical Materials

Typical Joint Designs

Bonding Process

Molding Considerations

Typical Optimized U/S Welding Parameters

Quality Considerations

Geometry Considerations​

High Volume/Automation Requirements​

Typical Materials

Typical Joint Designs

Bonding Process

Molding Considerations

Typical Optimized U/S Welding Parameters

Quality Considerations

Geometry Considerations​

High Volume/Automation Requirements​

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Typical Materials

Typical Joint Designs

Bonding Process

Molding Considerations

Typical Optimized U/S Welding Parameters

Quality Considerations

Geometry Considerations​

High Volume/Automation Requirements​

Welding SolutionsPrecise, Accurate and Flexible Welding Solutions

Dukane Advanced Welding Solutions for Medical Device Manufacturing:

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Geometry Considerations

High Volume/Automation Requirements

Geometry Considerations

High Volume/Automation Requirements

Geometry Considerations

High Volume/Automation Requirements