Create Config
Edit Name Description Configiration Type Type

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.

Robotic Surgical End of Arm Devices
Robotic Surgical End of Arm Devices

Robotic surgical end-of-arm devices, or end effectors, are critical components in roboticassisted surgery, providing enhanced dexterity and control of medical instrumentation. These devices can range from a multitude of tools such as graspers, scissors, dissectors, etc., and are a huge contribution to safer and more efficient procedures.

Typical Materials

  • PC​
  • PEI
  • PEEK
  • PSU
  • PA

Typical Joint Designs

  • Round Energy Director (Servo)
  • Staking Post Configurations

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 % 2-5%
Weld Speed 0.03 – 0.20”/Sec
Weld by Distance 0.006” – 0.020”
Dynamic Hold 0.01 – 0.02”
Dynamic Hold Speed 0.03 – 0.20”/Sec
Static Hold 0.2-0.5 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
Medical Instrument Handles
Medical Instrument Handles

Thermoplastic medical instrument handles feature lightweight and ergonomic designs for comfortable, precise tool manipulation during procedures or examinations. Their compatibility with imaging/X-rays sets them apart from metal handles, providing improved convenience and versatility for healthcare professionals.

Typical Materials

  • PC​
  • ABS
  • PSU

Internal components with expected relative motion should be weld incompatible.

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
  • 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” – 0.020”
Dynamic Hold 0.01 – 0.03”
Dynamic Hold Speed 0.03 – 0.20”/Sec
Static Hold 0.2-0.5 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

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: