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iQ Servo Ultrasonic Welding

Key Features

  • Consistent weld results with Dynamic Servo Motion Control
  • Strongest hermetic seal with Patented Melt-Match® Technology because it matches the melt flow of plastic with the speed of ultrasonic stack
  • Accurate and repeatable weld quality with Patented Melt-Detect™ Technology
  • Superior Data Acquisition with Industry leading 0.5 ms acquisition rate
  • Simple calibration procedure – no pneumatic components to adjust
  • Only one device required for calibration (Trigger Force Sensor)
  • All other parameters validated (no adjustment – functional tests only – distance, time & velocity)
  • Linear servo actuator with integral roller screw mechanism
  • 5” (127mm) stroke 20 kHz, 3.5” (89mm) 30/40/50 kHz with a teachable software travel limit
  • Top-of-stroke limit switch for automation application
  • Linear distance encoder with 1 μm resolution.
  • Programmable trigger force .1 lb resolution (1 lb 20 kHz version) Ideal for precise delicate assemblies
  • Programmable home position for reduced cycle time and setup optimization
  • FDA Compliance with features like multi-level password protection, process change audit history and documentation (21 CFR part 11)
  • No operator accessible adjustment knobs or controls ensures validated process remains unchanged. All mechanical changes require a specific tool.
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Testimonials: “We were looking for increased accuracy and repeatability in our welding process. Dukane’s iQ Servo was easily able to achieve our requirements and the simple iQ Explorer II application software was intuitive. This made process development and optimization very efficient and straight forward.” R&D Engineer at Surgical IOL at Alcon Laboratories. Novartis Alcon logo

“A small plastic stem was being damaged during welding and we were unable to optimize the weld settings on our pneumatic sonic welder to alleviate this issue. By integrating Dukane’s iQ Servo Ultrasonic Welder with patented Melt-Match® technology we eliminated the plastic port stem damage problem. The data collected during the servo process optimization proved to have a tighter standard deviation and a significantly higher process capability (Cpk). The ability to weld at a constant velocity and/or program a custom weld velocity profile greatly improved the welding process. The Melt-Match® feature was beneficial in getting a stronger weld.” Process Engineer at Bard Access Systems, Inc BARD logo

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Servo Controlled Ultrasonic Welding System with Patented Melt-Match®


Patented Melt-Match® Melt-Match® precisely matches the velocity of the ultrasonic stack with the melt flow velocity of the plastic material ensuring optimum molecular intermingling.

100% Electric/Servo
All-electric true servo technology eliminates the variability associated with pneumatic press components and provides unprecedented control to ultrasonic welding process.

0.5 ms Sample Rate Fast collection of data points during the weld improves repeatability and enhances reliability of the welding output and programmed quality controls.

Precise Calibration Displays all Weld parameters, limits and graphs from the weld cycle. 100% digital all-electric control simplifies the calibration and validation process.


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