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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.

Medical Gown
Medical Gown

In healthcare environments, medical gowns serve as personal protective equipment (PPE) by safeguarding wearers against the transmission of disease-causing microorganisms. They act as a protective barrier in case of contact with potentially infectious liquids or solids. Some gowns may be designed with pockets for medical instruments, ties/belts for closure, and sleeves to protect the wearer’s forearms.

Typical Materials

  • Non-woven PP​
  • Non-woven PET

Typical Joint Designs

  • N/A – Typically a male knurl/slit-stitch detail in the tooling to spot weld non-woven layers together

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 % N/A
Weld Speed 0.03 – 0.20”/Sec
Weld by Energy 100 – 600 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, up to 100 MM cycles
N95 Respirator
N95 Respirator

N95 masks are respiratory protective devices that filter airborne particle contaminants by trapping aerosols and droplets in their fibers. They are designed to form a seal around the nose and mouth of the wearer and can include a valve that reduces breathing resistance during exhalation.

Typical Materials

  • Non-woven PP​
  • Polyisoprene (PI) (straps)

Typical Joint Designs

  • N/A – Typically a male knurl detail in the tooling to spot weld non-woven layers together​

Bonding Process

  • Servo Ultrasonic Welding​
  • Probe Automation 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 % N/A
Weld Speed 0.03 – 0.20”/Sec
Weld by Energy 100 – 900 Joules
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​

  • 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, 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: