Products
- Ultrasonic Products
  - Ultrasonic Welders
    - Infinity™ with Melt-Match®
    - P220 Ultrasonic Welder
  - Automation Ready Ultrasonic Welding
  - Custom Ultrasonic Welders
  - Ultrasonic Hand Probe Systems
    - iQ Series Hand Held System
  - Proprietary User Interface/Software
    - iQ Explorer for Select Ultrasonic Welders
  - Additional Ultrasonic Products
  - Ultrasonic Film & Fabric Processing
  - Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic World
    
    Learn MoreChoose between Dukane's Infinity with Melt-Match technology or the P220 Ultrasonic Welder. Produce fast and consistently by programming ultrasonic stack velocity, force, and position throughout the entire welding process for stronger welds.Rugged Construction using the highest quality components provides superior performance, precision, and reliability. Compact, Single-Rail Linear Ball Slide Assembly System offers accurate positioning, stable movement, and friction-free travel.Reduce cycle time and get a custom-designed compact work cell with the patented Multi-Probe Control feature of our ultrasonic generators. Multiple probes are controlled with one ultrasonic generator, but each ultrasonic probe has its own unique weld recipe.Have more flexibility in your welding process with multiple modes. This includes Weld by Distance, Energy, Peak Power, Time, and Continuous Mode with process limits for all the parameters.Quick and Easy integration in automation systems. Seamlessly fits your control panel either vertically or horizontally and an intelligent cable management setup ensures a clean look and finishQuick and economical integration for automation systems. Seamlessly fits your control panel either vertically or horizontally. Integrated MPC(Multi-Point Controller) minimizes cabling to ensure a clean look and finish.Trigger by Power patented feature provides ability to accurately start the weld process once a programmed force is achieved. Coupled with weld by energy, this unit delivers the highest level of process repeatability of any probe system available today.The Multi-Point Control unit is designed for assembly systems where one ultrasonic power supply is sequenced to several ultrasonic probes. Our unique Control and Process Monitoring Profile is available for each individual probe when coupled with a Dukane iQ Series ultrasonic generator.Dukane’s iQLinQ™ is a proprietary communication protocol to give end-users an array of options to interface ultrasonic generators with automated systems.Let Dukane help you determine which ultrasonic welder is right for your application. Machine is constructed from tubular steel frame and 1 inch thick steel Blanchard ground top. Fork truck tubes and robust guarded castors in the base makes it easy to move and placeAutomation for manufacturers today require more flexibility and multipurpose machines to outpace their competition. Robot based work cells provide this flexibility and control for ultrasonic welding applications.Ultrasonic Generators with patented MPC controls multiple ultrasonic probes, minimizes capital investment, and simplifies machine programming.Rotary work cells are an economical solution for increasing throughput for small to medium sized assemblies . Rotary systems can be manual or semiautomatic in operation and are available in indexes of 2, 4, 8, 12 stations to name just a few.The HP and PG series hand probes feature an ergonomic soft grip design with attachments for use on counterbalance devices.The hand held welder has a soft grip and lightweight operator friendly hand probes. Lightweight unit with integrated handle makes the unit portable for plant mobility. Audible end of cycle notification alerts operator cycle is complete.Automation ready ultrasonic welding with proprietary iQLinQ™ communication protocol to interface ultrasonic generators with automated systems.Rotary horns provide higher, continuous power delivery. More power means faster, more consistent sealing. Focused energy and the “flywheel effect” of the rotary system allow for greatly increased sealing speeds and highly consistent seal integrity.Ultrasonic food processing involves a vibrating knife (guillotine) producing a nearly frictionless surface that minimizes buildup on the blade surface.The ultrasonic blade produces a nearly frictionless surface which minimizes sticking of food products and deforming. This process produces clean cuts without smearing when cutting multiple layers.Ultrasonic Cuts are cleaner than conventional cutters with minimal debris Ideal for cutting rubber, composite aerospace materials such carbon fiber, nomex and various honeycombs.Titanium is generally the preferred material for horns because it provides good fatigue strength, excellent acoustic properties and good surface hardness.iQ EZ Stapler is a small compact module designed to weld blister/clamshell packages. The system is activated by a foot-switch to free up the use of the operator’s hands to quickly and easily weld any size of package.Ultrasonic Fabric & film processing is the bonding, slitting, or sealing of fabrics and films containing thermoplastic material(s).i220 Bag Sealer provides a hermetic seal to thermoplastic valves on bags used for packaging powders, food, and hygroscopic products, which prevents product loss, moisture intrusion or pest infiltration.Ultrasonic provides clean and strong bonds by eliminating consumables or additives in the seam. Achieve molecular bonds at the seam no holes from sewing, or weak strands.Produce fast and consistently by programming ultrasonic stack velocity, force, and position throughout the entire welding process for stronger welds.iQ Servo Controlled Ultrasonic welding system provides single step cut and seal process to various film, fabric, and nonwoven materials. Ultrasonic eliminates material fraying and provides clean finish.Talk with an expert, contact us today. We're always ready to help.
- Laser Plastic Welding System
- Vibration Welding
  - 5000 Series
  - VW 6000 Series with Melt-Match®
  - LFVW 6970 with Melt-Match® technology
  - Dukane Vibration Welding systems provide clean, fast, well-suited for joining large parts, and the ability to produce high-quality joints.
    
    Learn MoreVW 5000 Series Vibration Welders Ultrasonic Welders set the industry benchmark when it comes to quality, standard and precision in plastic welding.This small machine packs all the features used in Dukane’s larger vibration welders into a smaller footprint when factory floor space is limited and the finished part size is 400mm x 500mm or less.Patented digital frequency drive delivers more power efficiency, reliability and flexibility for unique applications. Service spares, and drive upgrades are provided directly from Dukane eliminating dependency on third party manufacturers.Provides real time graphing of amplitude, pressure, and collapse distance, which gives users additional control to monitor, evaluate and troubleshoot their vibration welding process. Built in logical control eliminates the need of PLC programming expert for changing simple standard machine logic.Dukane’s WIDE part size machine was developed to weld wider and shorter parts such as intake manifolds and other parts sized up to 950 mm x 510 mm. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source.Well suited to assemble large parts (1550mm x 550mm) with sturdy mechanical features. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source. Robust frame with numerous cross members to support dovetail slide system for table.Dukane’s WIDE part size machine was developed to weld wider and shorter parts such as intake manifolds and other parts sized up to 950 mm x 510 mm. Heaviest-in-class, one-piece flame cut bridge stops unwanted vibration at its source.Provides the largest welding table in the industry with the smallest footprint, 25% smaller than current models.Melt-Match® technology matches the speed of the melt of plastic with the speed of the table to eliminate the displacement of liquid and solid plastic in the weld joint which reduces degradation and oxidation of the material.Talk with an expert, contact us today. We're always ready to help.
- Spin Welders
  - Servo Weld ™ Plus Spin Welder
  - Spin Welding
    
    Learn MoreServo Weld Plus Spin Welder electric press system uses two servo motors for precise control & accuracy in welding plastic assemblies w/circular weld joints.Talk with an expert, contact us today. We're always ready to help.
- Particulate Free Welding
  - Hot Gas Welding
  - Infrared Welding - TH3
  - Rotary Infrared Welding
  - Two-Phase Thermoforming
  - Eliminate particulate from your welding process and produce cleaner, stronger plastic parts with better aesthetics with latest welding technologies.
    
    Learn MoreOur patented procedure for particle-free and oxidation-free welding.TH3-Thermal Hybrid is one platform designed to offer Infrared, Hot Plate & Hot Gas Welding solutions. Users can buy one system and quickly configure the TH3 to weld using one of the three welding processes (Infrared, Hot Gas and Hot Plate) by quickly changing between different tools and components in the system.Dukane’s rotary infrared welding system is tailored for assemblies falling within a footprint of 200mm x 250mm or less, requiring a faster cycle rate than cannot be provided by conventional hot plate or infrared welders. This unique machine provides a non-contact infrared welding solution that is capable of producing welded assemblies as rapidly as every 8 seconds as compared to conventional IR welding machines that run at a rate of 30-40 seconds per cycle.The Two-Phase Thermoforming can be used for all thermoplastic materials; therefore, plastic-plastic and plastic-metal can be assembled without any problems.Talk with an expert, contact us today. We're always ready to help.
- Hot Plate Welders
  - Hot Plate Welder - TH3
  - After the plastic interfaces have melted, the parts are brought together to form a molecular, permanent, and often hermetic bond.
    
    Learn MoreTH3 hybrid platform with rapid changeover between Hot Plate, Hot Gas, and Infrared tools and components delivers cost savings for future programs. Talk with an expert, contact us today. We're always ready to help.
- Rotary Ultrasonic Solutions
  - Rotary Ultrasonic Solutions for Packaging
  - Rotary Ultrasonic Sealing for Nonwovens
  - Dukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials.
    
    Learn MoreDukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials.Soniseal™ WD bonders have full wash-down capability and can remain on the machine during cleaning. No bagging necessary!Rotary horns provide higher, continuous power delivery. More power means faster, more consistent sealing. The Sonisolution™ RS Series of rotary ultrasonic sonotrode assemblies offers many benefits for your customers. Some of those benefits include the capability of reducing raw materials, increasing process speeds, improving product quality, and decreasing equipment maintenance. Aurizon® patented technology allows those with the technical knowledge to integrate high power ultrasonic capability into their machine designs.The Soniseal™ 40 Series uses patented Aurizon® rotary ultrasonic technology to enable new capabilities in packaging applications. The Series consists of pre-engineered systems that deliver performance and savings by increasing productivity and reducing costs when implemented. Dukane's Rotary Ultrasonic Solutions for sealing non-wovens is a technology designed to provide efficient and reliable sealing of non-woven materials. A Dukane patented process where elastic strands are entrapped between the two layers of Nonwoven materials using ultrasonic energy. Directly attach elastic strands to the substrate web and avoid all costly adhesive materials and complex adhesive delivery systems.We have solutions for seaming materials together utilizing our proven and patented technology to the attachment of tabs and other articles without the need for glue.Ultrasonic Lamination systems use a low-density anvil pattern to tack materials together while leaving the majority of the web open for other functional attributes (e.g. absorbency).Ultrasonic Cut and Seal technology offers a variety of solutions for a broad range of end-use applications.Talk with an expert, contact us today. We're always ready to help.
Markets We Serve
- Automotive
- Medical
- Electronics
- Non-woven
  - Full Panel Elastic With Ultrasonic Bonding
  - Face Mask Construction
  - Disposable Gown Construction
  - Ultrasonics provides the cleanest, fastest, and most efficient method for bonding non-woven materials. Rotary bonding, plunge bonding, single step cut and seal of non-woven materials or...
    
    Learn MoreOur Adhesive Free Elastic Entrapment solution consists of a high-speed ultrasonic bonding system to attach elastic strands to nonwovens without adhesive. Elastic strands and nonwoven substrates are bonded as they pass through a high-speed rotary ultrasonic drum and anvil.Get clean process and seam without any consumables or additives in the seam. Achieve molecular bonds at the seam no holes from sewing, or weak strands. Assemble variety of non woven materials including SMS, Polypropelene Spun, SSS, SMMS.Get clean process and seam without any consumables or additives in the seam. Reduce maintenance downtime by eliminating glue applicator and spray nozzles from the process. Eliminate raw material wastage at the start and stop of the cycle caused by idle heat bars in heat sealing.Talk with an expert, contact us today. We're always ready to help.
- Food
- Packaging
- Automation
- Ultrasonic Cutting
Company
Resources
- FAQs
- Our Processes
  - Ultrasonic Plastic Welding
  - Vibration Welding
  - Laser Welding
  - Spin Welding
  - Infrared Welding
  - Hot Plate Welding
  - Ultrasonic Food Cutting
  - Ultrasonic Film & Fabric Processing
  - The plastic welding process creates a molecular bond between two compatible thermoplastics. Three main steps to any weld: pressing, heating, and cooling.
    
    Learn MoreUltrasonic thermoplastic welding process is the joining or reforming of materials through the use of heat generated from high-frequency mechanical motion.Compared to ultrasonic welding, vibration welders operate at much lower frequencies, higher amplitudes and much greater clamping force.Laser welding is a non-contact joining method that uses a laser beam to melt the plastic in the joint area by delivering a controlled amount of energy to a precise location. Precision in controlling the heat input is based on the ease of adjusting the laser beam size and the range of methods available for positioning the beam. Most thermoplastics can be welded using a proper laser source and appropriate joint design.This process works through rotational motion of one part relative to the other. This results in surface friction that leads to heat generation and the formation of a melt layer at the joint. Spin welding typically has weld times from one-half to five seconds. Dukane’s spin welders can handle parts from approximately one-half inch (12 mm) diameter using high speed motors up to nine inches (225 mm) diameter using high torque motors.Another non-contact welding method is infrared welding that uses radiation to transfer heat to the plastic parts. It follows the same fundamental steps as hot plate welding. Two different approaches to infrared welding have emerged. One of the systems uses an electrically heated metal plate which, in some cases, is coated with a ceramic. In the other system, the standard heater plate is replaced with infrared emitters clamped and spring-loaded on either side of a movable platen.Hot plate welding process uses conduction, convection and/or radiation from an actual heated platen to melt the fraying surfaces of the plastic parts.Ultrasonic food processing involves a vibrating knife producing a nearly frictionless surface which does not deform food products and to which they do not stick. The surface cleanly cuts or slits products including fillers such as nuts, raisins, dried fruit or chocolate morsels without displacement or plowing.Typical fabric & film installations are multiheaded systems that take advantage of Dukane's narrow profile thrusters’ close center-to-center positioning.Talk with an expert, contact us today. We're always ready to help.
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What is Elastic Entrapment with Ultrasonic Bonding?

A Dukane patented process where elastic strands are entrapped between the two layers of Nonwoven materials using ultrasonic energy. Ultrasonic Energy produces clean molecular bonds next to the elastic strands that directly entraps tensioned elastic within the fabric.

As shown in the video tensioned elastic strands pull the nonwoven material down into the very small grooves that are created with the entrapment pattern on the anvil. When bonded material leaves the process, the strands retract and become larger in diameter; therefore, are entrapped in that very small area.

The elastic strand are firmly secured between the nonwoven substrates without adhesive. The resultant fabric (composite) is robust to temperature, time and end used emollients maximizing product performance.

Overview

Get clean process and material without any consumables or additives in the strands
Achieve molecular bonds no mess from adhesives, or weak strands from heat
Assemble variety of nonwoven materials including SMS, SSS and PP Spun bond
Eliminate the cost of adhesive and the glue delivery system and get up to 5X faster cycle rate
Reduce maintenance downtime by eliminating glue applicator and spray nozzles from the process
Increase production uptime and lower process waste through process simplification and robustness
With a wide array of ultrasonic bonding technologies every elastic attachment application can be produced using ultrasonic joining

Play

Key Features

Ultrasonic bonding provides:

Clean, simple, and robust process for creating elasticized materials that have minimal creep
Eliminates the need for costly adhesives and complex adhesive delivery system
Commercially capable high speed process up to 1000 meters per minute
Eliminates non-value-added complexity by directly attaching the tensioned elastic to the film / fabric substrate, No adhesive or complicated adhesive delivery systems.
End products produced by this process can range from narrow containment flaps and leg cuffs to wide waist panels and can be constructed with lighter-weight materials without concern for adhesive bleed-through.

Elastic Panel Construction

Robust, high-speed process solution for creating elasticized materials
Easily bonds multi-strand applications from 25mm – 450mm wide panels

Containment Flap

Eliminating adhesive allows the finished product to be softer, odor-free, and breathable
Use lighter weight fabrics so the final product is thinner and more comfortable when wearing

Leg Cuff Attachment

High-speed, continuous construction of leg cuff materials without applying costly and complex adhesives
Strong bonds and improves elastic performance

Elastic Entrapment-Six to Sixteen Strands

Play Video

Robust Process Unaffected by Disruptions

Ultrasonic bonding provides a reliable and robust solution to this process. It is unaffected by the following conditions and does not need to stop the production.

Unaffected by splices in the web
Web weave disruptions
Elastic strand movement
Elastic splices or knots

Since the strands are not attached but just entrapped the end product is not stiff. Flexible process, flexible products:

Produces materials from 25 mm-200mm width with the same setup
Softer feel
Breathability
Eliminates skin irritations caused by the stiffening effect of adhesive
Smell of adhesive in the diaper

Blogs

Advantages of Ultrasonic Sealing for Packaging Mono Materials and Biodegradeables

August 29, 2023

When it comes to mono materials and biodegradables, ultrasonic sealing can offer several benefits

Solutions Provider, not an Equipment Supplier!

February 1, 2023

Plastic bonding projects are inherently challenging—they require specific knowledge and experience to implement successfully. Without proper technology selection, equipment/tooling design, and process implementation, your product launch can go from smooth to disaster—before you’ve even begun!

Process Validation for Medical Device Manufacturers

January 26, 2023

What is Process validation? According to Wikipedia, it is the analysis of data gathered throughout the design and manufacturing of a product to confirm that the process can reliably output products of a determined standard. As anyone who has gone through a validation process would tell you, the accuracy and repeatability of the equipment used in the manufacturing process of medical devices are critical to success.

Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic World

January 17, 2023

Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic World. Pneumatic press systems are so 1980s… well, actually more like the 17th Century, but that’s a different story. From the beginning, the prime mechanisms used to initiate the required force for a successful ultrasonic weld were a combination of pneumatic valves and cylinders.

What is the right material for making Ultrasonic Horns?

June 28, 2021

Ultrasonic horn stretches and shrinks in length during the plastic welding process like a spring. For example, a 20 kHz horn is typically a one-half wavelength long resonant bar, whose molecules are constantly expanding and contracting 20,000 times per second. Consequently, the horn is continually under compression or tension. That’s why, for manufacturing ultrasonic horns…

Which Applications are Best Suited for 2μm Laser Welding?

June 4, 2020

While you will find 2μm lasers being used in a broad range of industries including automotive, general industrial, films, and packaging, the majority of 2μm welding demand is coming from the medical industry. Typical laser welding applications include: microfluidic devices, tubing, bags, connectors, catheters, on-body devices, diagnostic cassettes, fluid chambers and tanks, filtration devices, and more. Microfluidics, diagnostic cassettes, and assays often require components to be transmissive…

12 Advantages of Laser Plastic Welding

February 11, 2020

The use of various plastics in manufacturing has grown immensely in the last 15 or so years. Weight savings, optical requirements, and flexibility to name a few reasons push the envelope of legacy materials and often times leave plastics as the only logical choice to meet design requirements.

Reduce Flash, Get Stronger Welds, & Lower Residual Stress with Dynamic Weld Velocity

January 15, 2020

Assembling medical devices and other medical components are demanding. Consistently producing good parts, in a validated process, while recording, storing, and analyzing data points is imperative. Utilizing an ultrasonic welding process for assembly is widely accepted for medical devices and components because it is a fast, clean, easy to validate, repeatable assembling process. However, the…

Benefits of Melt-Match®

November 11, 2019

Melt-Match® is known in the plastic industry to improve all the phases of the plastic welding process with servo-driven control and precision. Check out the following video showing the difference between pneumatic vs servo ultrasonic welding with patented Melt-Match®. Improves confidence in total quality with a tighter standard deviation of dimensional accuracy and weld strength…

The 4 Pillars of Laser Polymer Welding using 1 micron Laser

October 18, 2019

Mastering the 4 pillars of Laser Polymer Welding using 1 micron Laser will provide an excellent foundation for you to design-in the technology. Pillar #1 – IR (Infrared) Transparent Upper Layer The first layer of material that the laser beam encounters (the IR Transparent Layer) must allow a certain portion of the laser energy to…

What is Elastic Entrapment with Ultrasonic Bonding?

Overview

Key Features

Elastic Entrapment-Six to Sixteen Strands

Blogs

Advantages of Ultrasonic Sealing for Packaging Mono Materials and Biodegradeables

Solutions Provider, not an Equipment Supplier!

Process Validation for Medical Device Manufacturers

Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic World

What is the right material for making Ultrasonic Horns?

Which Applications are Best Suited for 2μm Laser Welding?

12 Advantages of Laser Plastic Welding

Reduce Flash, Get Stronger Welds, & Lower Residual Stress with Dynamic Weld Velocity

Benefits of Melt-Match®

The 4 Pillars of Laser Polymer Welding using 1 micron Laser

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