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Overview

Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry. We offer a comprehensive range of products and services to help manufacturers design, develop, and manufacture high-quality, reliable, and cost-effective diagnostic devices.

Inline Intravenous Filter
Inline Intravenous Filter

Inline filters protect vacuum pumps and outlet gas environments. Easy-to-use sterile and disposable inline filters contain a hydrophobic PTFE membrane. Ideal for confining and isolating infectious and hazardous materials in vacuum systems and protecting your laboratory.

Typical Materials

  • PMMA (Acrylic)​
  • SAN
  • PC​
  • PES
  • PP
  • PET
  • PA (Nylon)
  • PTFE (Membrane)

Typical Joint Designs

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

Bonding Process

  • Servo Ultrasonic Welding - Typical
  • 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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % 2-7%
Weld Speed 0.03 – 0.20”/Sec
Weld by Distance 0.008” – 0.015”
Dynamic Hold 0.01 – 0.02”
Dynamic Hold Speed 0.03 – 0.20”/Sec
Static Hold 0.2 Sec

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 0.250” 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
Intravenous Cannula
Intravenous Cannula

An intravenous (IV) cannula typically administers medications or drains fluids. This device consists of a thin, flexible tube with a pointed tip that is inserted directly into a vein on the back of the hand or forearm. The other end is connected to an IV bag or syringe. IV cannulas come in various sizes for different patient needs and are essential for delivering IV therapies in healthcare.

Typical Materials

  • PC​
  • PP
  • PA (Nylon)

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​

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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % 2-7%
Weld Speed 0.03 – 0.20”/Sec
Weld by Distance 0.008” – 0.025”
Dynamic Hold 0.01 – 0.03”
Dynamic Hold Speed 0.03 – 0.20”/Sec
Static Hold 0.2 Sec

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 0.250” 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
Intravenous Infusion Bag and Port
Intravenous Infusion Bag and Port

Intravenous (IV) bags are sterile, single-use medical storage containers designed for the preservation and delivery of fluids, nutrients, and medications directly into a patient’s vein. IV therapy is a very common medical procedure as the transparent bags allow for efficient monitoring and administration of fluids.

Typical Materials

  • EVA
  • PET
  • PVC
  • PE
  • PP

Typical Joint Designs

  • N/A

Bonding Process

  • Servo Ultrasonic Welding​
  • Servo SynQro - Single Operation Pouch-Spout Welding

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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % N/A
Weld Speed 0.03 – 0.20”/Sec
Weld by Energy 200 – 800 Joules
Dynamic Hold 0.01 – 0.02”
Dynamic Hold Speed 0.03 – 0.20”/Sec
Static Hold 0.2 Sec

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​

  • Consistent and even material layer thickness across 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

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: