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Thin Wall (2.2-2.7 MM) Ultrasonic Welding

No Read or Marking

Effortlessly weld your car radars onto 2.2mm painted walls or other components onto walls with thicknesses ranging from 2.0mm to 2.7mm, guaranteeing no read, visible marks, or signs are left behind on the painted surface.

Paint Compatibility

It seamlessly welds painted surfaces without compromising the integrity of the weld, preserving both aesthetic and protective qualities of painted components.

Integration Flexibility

The technology offers easy integration into existing assembly lines or standalone machines, enhancing production capabilities with minimal disruption.

Reliability

Dukane’s Thin Wall Ultrasonic Welding Technology has proven reliability in diverse production environments, ensuring high productivity and minimal downtime.

Exceptionally Strong Welds

The technology produces welds with impressive strength, with PDC connections enduring pull-out forces of up to 350N, making it ideal for demanding applications.

Overview

Welcome to the forefront of ultrasonic welding innovation! DUKANE proudly presents our patented Ultrasonic Welding technology for assembling parts on painted walls. Extensive testing confirms zero markings on various painted bumper thicknesses, ensuring the welded parts maintain a pristine appearance.

WHAT IS THIN WALL WELDING USING ULTRASONIC TECHNOLOGY?

At Dukane, we specialize in ultrasonic welding solutions that excel in joining PDC brackets, masks, or stiffeners onto a range of automotive components such as bumpers, wheel arches, spoilers, and rockers with unparalleled precision and strength and without any read or mark on the painted surface. Our 50 kHz technology, coupled with a servo actuator, delivers optimal results ensuring seamless integration and exceptional performance

APPLICATIONS AND MATERIALS

Our Thin Wall Welding technology is primarily employed in automotive applications, particularly for welding PP to PP TD25 painted parts.

Common applications include

  • Bumpers
  • Spoilers
  • Rocker Panels
  • Wheel Arche

KEY TECHNICAL FEATURES

High-Gain Full-Wave or 1.5-Wave Horn

The technology utilizes a high-gain full-wave or 1.5-wave horn, paired with an iQ Auto-Plus Ultrasonic Generator and a 600W probe. This combination ensures optimal weld strength and precision, delivering consistent and high-quality results. The advanced horn design enhances the efficiency of the ultrasonic welding process, making it more effective for challenging applications.

Patented “Trigger by Power” Technology

Dukane’s patented “Trigger by Power” technology ensures controlled speed throughout the weld, significantly reducing the risk of surface imperfections. This feature allows for precise control over the welding process, resulting in clean and flawless welds. The technology enhances the overall quality of the welded components, making it suitable for high-stakes manufacturing environments.

Strategically Smaller Collapse Distance

The collapse distance is strategically smaller than the part’s thickness, guaranteeing a seamless finish. The precise control over the welding parameters ensures that the welded parts fit together perfectly without any visible defects or inconsistencies.

Complete Servo Module Options

Dukane offers complete servo module options, including rotary linear servo or linear servo, for streamlined integration into manufacturing processes. These servo modules provide enhanced control and automation, improving the efficiency and accuracy of the welding process. The availability of different servo options allows manufacturers to choose the configuration that best suits their specific needs and production requirements.