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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.

Microfluidic Device and Cartridge
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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % 2-5%
Weld Speed 0.03 – 0.20”/Sec
Weld by Distance 0.004” – 0.012”
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
Diagnostic Tests
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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % 2-5%
Weld Speed 0.03 – 0.20”/Sec
Weld by Distance 0.006” – 0.020”
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
Continuous Glucose Monitor - Diabetes Care
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 Start Velocity 0.010 – 0.030”/Sec
Melt-Match % 2-5%
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, 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: