Dukane / Products / Ultrasonic Welding Products / Additional Ultrasonic Products / 50 kHz Ultrasonic Staking of Plastic It's the connection that counts

50 kHz patented Ultrasonic Plastic Staking/Welding

Cleaner Welds

Immediate melting at the contact point, no dust or debris formation

Defect Free Parts

Avoids tab fractures, A-surface marks, and parasitic welds

No Extra Components

No need for hydraulic dampening or servo speed controls 

Faster cycle Times

From 7 seconds to approx. 4 seconds, less heat, more output

Automation Ready

Patented 50 kHz system is integration-friendly and optimized for high-speed, high-precision production lines. Currently in use across multiple OEM and Tier 1 programs 

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50 kHz Ultrasonic Staking

Overview

Patented 50 kHz ultrasonic staking technology delivers a breakthrough solution for joining amorphous thermoplastics used in today’s automotive assemblies, meeting the demand for lightweight, fuel-efficient vehicles. Designed to address the persistent challenges of traditional 30–40 kHz systems, this high-frequency process provides precise, localized melting at the top of plastic tabs or bosses, thereby eliminating fractures, surface blemishes, and parasitic welds. With shorter cycle times, cleaner welds, and no need for additional speed-control hardware, Dukane’s 50 kHz system is optimized for automated production environments. Backed by global patents and proven across major OEM platforms, it sets a new standard for quality, efficiency, and process control in automotive plastic staking.

KEY TECHNICAL FEATURES

Dukane 50 kHz Ultrasonic Staking System Includes: 

  • iQ Auto+ Generator (600W) 
  • Built-in Ethernet/IP 
  • Optional: Profibus, Profinet, CC-Link, EtherCAT, PowerLink 
  • Rigid Probes with Side/Top Connector Placement 
  • Compact design for tight automation footprints 
  • Consistent energy delivery and quick response time 

Is our Ultrasonic Cutting Systems the right fit for your application?

Easily replicate a proven welding process from one Infinity system to another with the 100% digital all-electric control. No adjustments to pneumatics are needed.

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