Frequently Asked Questions

Fumes or smoke are an indication of thermal decomposition of the thermoplastic material. So process optimization is critical.

Yes, in fact the laser welding systems are flexible and the systems are easy to automate.

No, due to the 2-micron laser beam is absorbed by the polymer itself.

Yes and Dukane will advise you for the optimum joint design. In many cases flat-on-flat surfaces are acceptable.  A good fit between mating surfaces is critical.

It is not required when using the 2-micron laser.

This depends on the material properties and thickness of the upper part.

To date, we have welded parts up to 700mm diameter. There are really no limitations as each system is custom designed based on the customer’s requirements.

Not necessarily.  Some parts can be clamped using metal (aluminum or stainless steel).

Yes, in many cases an annual calibration is sufficient, but calibration frequency is guided by your quality control requirements.

Both could be clear or both could be pigmented or just the bottom part can be pigmented.

Our laser work cell enclosures are Class 1 CDRH certified with laser-safe glass viewing window.

Moderate curvature is possible without any special tooling.

Most commonly used thermoplastics can be welded with the exception of fluoropolymers.

Yes. Dukane welding systems are engineered for easy integration into high-speed,

high-volume automation environments. Features like servo actuation, Ethernet/IP and OPC-UA connectivity, barcode scanning, and modular configurations enable this smooth transition.

Absolutely. Dukane systems include CFR 21 Part 11 compliant features such as multi-level password protection, weld log tracking, barcode scanning, and automatic weld data backups for full traceability and audit-readiness.

Yes. Ultrasonic and laser welding are two advanced joining methods frequently used in the medical device industry to create strong, clean, and precise bonds between components—without the use of adhesives, which can introduce contaminants or biocompatibility concerns. Here’s how each process works and how they’re applied in medical device assemblies:

Ultrasonic Welding

How it works:

• High-frequency (typically 20-40 kHz) ultrasonic vibrations are applied to thermoplastic materials under pressure.

• The vibrations create localized frictional heat at the interface of the components, causing the material to melt and fuse.

• Once the ultrasonic energy stops, the plastic solidifies quickly under pressure, forming a bond.

Advantages:

• No need for adhesives or solvents.

• Fast cycle times (often under a second).

• Clean, particulate-free welds with high consistency.

• Easily automated and suitable for high-volume production.

Laser Welding

How it works:

• A focused laser beam (typically near-infrared) is used to melt the interface of two components.

• One part is usually transparent to the laser wavelength, allowing the energy to pass through and heat the underlying (absorptive) component. Welding clear-to-clear assemblies without additives is also an option.

• The localized melting fuses the materials together when clamped.

Advantages:

• Very clean, precise welds.

• Minimal thermal distortion—ideal for small or delicate parts.

• Enables welding of complex geometries and clear parts.

• Hermetic sealing possible for fluid-handling components.

Yes. Dukane welding systems are built to meet cleanroom requirements and are designed with energy-efficient and environmentally responsible features to support both product safety and sustainability goals.

Dukane’s applications engineering team offers a suite of services including:

• Feasibility evaluations and joint design consulting

• Material testing and prototype tooling

• In-lab welding and data collection

• Process troubleshooting and optimization

These services help ensure the medical device is production-ready, meets quality standards, and can be manufactured efficiently at scale.

Ultrasonic and laser plastic welding are widely used across key medical segments including diagnostics, drug delivery, patient monitoring, surgical instruments, implantable components, and fluid management systems. These technologies enable precise, clean, and strong bonds ideal for microfluidic cartridges, auto-injectors, sensors, surgical tools, and IV components. They support biocompatibility, sterilization, and high-throughput production while avoiding adhesives that could compromise device performance or safety, making them essential in regulated medical manufacturing environments.

Ultrasonic and laser welding enable medical device assemblies to meet critical requirements such as hermetic sealing, biocompatibility, and sterilization resistance—without the use of adhesives. Both methods are cleanroom-compatible and support regulatory compliance through consistent, traceable processes. Ultrasonic welding offers high mechanical strength and extremely fast cycle times, making it ideal for high-throughput production. Laser welding provides exceptional precision and cosmetic quality, especially for transparent or microfluidic components. Together, these processes deliver strong, reliable, and sterile joints suitable for demanding medical applications.

Dukane systems are used for a vast range of medical devices, including wearable devices, surgical instruments, respiratory devices, in-vitro diagnostics, fluid containment and filtration systems, and more. 

Probable Causes and Solutions:

• The insert is too long, or the hole is too shallow.
  • Use a shorter insert or make the hold deeper.
• There is too much interference between the hole and the insert.
  • You need to decrease interference.
• The insert is being driven too deep.
  • You need to decrease the primary weld parameter.

Probable Causes and Solutions:

• The insert is pushed in before the plastic has melted.
  • Try using pre-triggering, reduce the down speed and/or gauge pressure, or use slower iQ Servo Weld Speed.
• The weld force is too high.
  • You need to reduce the gauge pressure.
• The boss wall is too thin.
  • You need to increase the wall thickness of the boss.
• There is too much interference between the insert and the hole.
  • You need to decrease interference.
• Weak molded “knit” or “weld” lines.
  • Ensure correct molding parameters.

Probable Causes and Solutions:

• The plastic is not melting consistently around all inserts.
  • You need to increase the amplitude.
• Inserts are pushed into the plastic before the plastic has melted.
  • Use slower iQ Servo Weld Speed, use hydraulic speed control, reduce the down speed, or use pre-triggering.
• Inserts are seated at different heights.
  • Weld to a position or absolute distance, use pre-trigger, or level fixture.

Probable Causes and Solutions:

• There is insufficient interference between hole and the insert.
  • Ensure proper hole size per insert the manufacturer guidelines.
• The screw bottoms out in the hole. (Applies to internally threaded insert)
  • Try using a shorter screw or increase the depth of the hole.
• The insert gets pushed into the plastic before the plastic melts.
  • Use slower iQ Servo Weld Speed, use a hydraulic speed control, increase the amplitude and/or decrease the gauge pressure, or use pre-triggering.
• The ultrasound remains on after insertion is complete.
  • Reduce the primary weld parameter.
• The horn retracts before the plastic around the insert is solidified.
  • You need to increase the hold time.

Probable Causes and Solutions:

• There is too much interference between the hole and the insert.
  • Increase the hold diameter (if possible) or use a smaller insert.
• The area of the part being inserted is not being rigidly supported.
  • Support the part directly under the boss or install a metal post directly under the part being inserted.
• The down speed is slow.
  • Increase the down speed/increase iQ Servo weld speed.
• Insertion force too low.
  • Increase weld force by increasing weld speed or pneumatic down force.

Probable Causes and Solutions:

• The ultrasound is not on long enough.
  • You need to increase the primary weld parameter.
• Flash fills the hole (Applies to an internally threaded insert).
  • Increase the depth of the hole.
• There is insufficient gauge pressure and/or power.
  • Increase the gauge pressure or change to a higher power rated generator.

Probable Causes and Solutions:

• The head has not solidified before the horn retracts.
  • You need to increase the hold time.
• The horn tip is heating and not allowing the head to solidify.
  • You need to cool the horn tip or use afterburst.

Probable Causes and Solutions

• There is a sharp corner near the base of the stud.
  • Radius the stud at the base.
• Trigger Force is too high.
  • Decrease Trigger Force.
• The Amplitude is too high.
  • Pre-trigger the ultrasound, decrease the amplitude by changing to a lower gain booster or reduce amplitude percentage setting, or use amplitude profiling to decrease at end of cycle.
• The downstroke speed is too fast.
  • Use hydraulic speed control or use a slower downstroke speed.

Probable Causes and Solutions:

• There is a sharp corner near the base of the stud.
  • You need to radius the stud at the base.
• The stud Is not centered in the horn cavity.
  • Center the stud under the horn cavity.
• Too much pressure is applied before the ultrasound is activated.
  • Use pre-triggering or decrease down speed or iQ Servo Weld Speed.
• The trigger force is too high.
  • Reduce the trigger force.

Probable Causes and Solutions:

• The part is not supported directly beneath the stud being staked.
  • Support the fixture with a metal post under the stud being staked.
• The trigger force is too high.
  • Reduce the trigger force or use pre-triggering.
• Weld distance is too high.
  • You need to decrease weld parameter.
• Weld Amplitude is too high at end of cycle.
  • Use Amplitude profiling to decrease at end of cycle.

Probable Causes and Solutions.

• The hole diameter relative to the stud diameter is too large.
  • You need to reduce the hold diameter.
• The holding force was removed before the stud head could solidify.
  • If using a dual pressure system, use pressure 2 in the hold portion of the weld cycle (Pressure 2 should be higher than Pressure 2), use Dynamic Hold to ensure appropriate compression during hold phase, increase the hold time/distance, increase the stud diameter, or reduce the size of the staking cavity.
• Insufficient force is being applied to the staked head during the hold time.
  • Use Dynamic hold to ensure appropriate compression during hold phase.

Probable Causes and Solutions:

• The staking cavity is too large.
  • Change to a smaller cavity in the horn.
• The volume of plastic in the stud is insufficient.
  • You need to increase the stud height/diameter.
• The stud is melting at the base.
  • See the problem section below titled, “The base is melting before the head forms”.

Probable Causes and Solutions:

• The staking cavity is too small.
  • Use a larger cavity in the horn.
• The volume of plastic in the stud is excessive.
  • Decrease the stud height and/or the diameter.
• The stud is not centered in the horn cavity.
  • Center the stud under the horn cavity.

Probable Causes and Solutions:

• There are sharp internal corners/thin sections.
  • Try to radius all sharp corners and damp any damaged area (if possible).
• There is excessive amplitude.
  • Try reducing the amplitude by changing to a lower gain booster or reduce amplitude percentage.
• There is excessive weld time.
  • Try decreasing the primary weld parameter, increasing the amplitude, increasing the gauge pressure, and increasing the iQ Servo Weld Speed or use Melt-Match® speed profiling.
• There is internal part stress.
  • Ensure correct molding conditions, perform mold flow analysis, follow standard design practice to reduce residual stress in molded parts, reduce the amplitude by changing to a lower gain booster or reduce amplitude, and use amplitude.

Probable Causes and Solutions:

• There are sharp internal corners/thin sections.
  • Try to radius all sharp corners and damp any damaged area (if possible).
• There is excessive amplitude.
  • Try reducing the amplitude by changing to a lower gain booster or reduce amplitude percentage.
• There is excessive weld time.
  • Try decreasing the primary weld parameter, increasing the amplitude, increasing the gauge pressure, and increasing the iQ Servo Weld Speed or use Melt-Match® speed profiling.
• There is internal part stress.
  • Ensure correct molding conditions, perform mold flow analysis, follow standard design practice to reduce residual stress in molded parts, reduce the amplitude by changing to a lower gain booster or reduce amplitude, and use amplitude.

Probable Causes and Solutions:

• The part does not match CAD data used to cut tooling.
  • Try polishing tooling and/or recut with larger offsets.
• There is too much energy is being transmitted to the part.
  • You need to reduce the gauge pressure, reduce the weld time/primary weld parameter, reduce the amplitude by changing to a lower gain booster or reduce amplitude percentage, use a slower downstroke speed, increase the amplitude by changing to a higher gain booster to decrease weld time, increase IQ Weld Speed or use Melt-Match® speed profiling.
• The horn temperature increase causes marking.
  • Try to cool the horn using forced convection, confirm that the horn and booster interfaces are clean and flat, ensure horn, booster, and transducer interfaces are appropriately torqued per Dukane specifications, and visually check the horn for cracks.
• The use of raised letting causes marking.
  • Use recessed lettering or relieve the horn around the lettering.
• The part doesn’t fit the tooling properly.
  • Check the tooling for proper support, place polyethylene film between the horn and the part or use Dukane film feeder, check for cavity to cavity variations, and redesign the remanufacture the fixture.
• There is oxide from the horn being transferred to the part.
  • Place polyethylene film between the horn and the part or use Dukane film feeder, use a chrome-plated horn and/or fixture, or use polished Titanium horns.
• The filler content varies in part.
  • Ensure correct molding conditions and reduce the amount of filler in the plastic.

Probable Cause and Solution:

• There is too much energy being transmitted to the part.
  • Try reducing the gauge pressure, reduce the weld time/primary weld parameter, reduce the amplitude by changing to a lower gain booster or reduce generator amplitude percentage setting, use slower downstroke speed, increase the amplitude by changing to a higher gain booster to decrease weld time, and increase IQ Servo Weld Speed or use Melt-Match® speed profiling.

Probable Causes and Solutions:

• There is insufficient energy being transmitted to the part.
  • Try increasing the gauge pressure, increasing the weld time/primary weld parameter, changing to a higher gain booster to increase the amplitude, decreasing iQ Servo Weld Speed, and changing to a higher power rated generator.
• The energy is being absorbed into the fixture.
  • Try changing the type of fixture being used.

Probable Causes and Solutions:

• There is a warped part(s).
  • Try checking part dimensions, ensure there are correct molding conditions, use a higher Trigger Force/Trigger Delay, use a higher Hold Pressure, and increase Melt-Detect™ percentage.
• The energy director varies in height.
  • Redesign the energy director to ensure uniform height and use an interrupted energy director.
• There is lack of parallelism between the horn, the fixture, and the part.
  • Try level tooling to the part and ensure correct part dimensions.
• Wall flexure is occurring.
  • Add ribs to the part and incorporate fixture component to prevent outward flexure.
• The knockout pin location is in the joint area.
  • Redesign the part so the knockout pin is not in the joint area. (Make sure knockout pins are flush with the surface).
• There is insufficient support in the fixture.
  • Redesign the fixture to improve the support in critical areas (underneath weld region), use a more rigid fixture, and add a rigid backup to unsupported sections in resilient regions.
• The part dimensions are incorrect.
  • Ensure correct part dimensions and molding conditions.
• The parts are improperly aligned.
  • Check for part shifting during welds, the alignment of mating parts, and for parallelism of the horn, the part, and the fixture.
• There is a lack of intimate contact around the joint area.
  • Ensure correct part dimensions and tolerances, ensure knockout pin marks are not in the joint area, and check for misalignment of the mating part halves.
• Non-uniform horn contact is occurring.
  • Check for sinks in the molded parts, check the fit of the part to the horn, and check for proper support in the fixture.
• There is mold release on the joint surface(s).
  • Clean the mating surface and use paintable grade mold release.
• There is a non-uniform distribution of filler/reinforcement in the plastic material.
  • Ensure correct molding conditions and check the mold design.
• There is a material or resign grade incompatibility problem.
  • Consult with a resign supplier(s) or Dukane Application Engineering.
• The Regrind percentage varies.
  • Consult with the molder and ensure correct molding conditions.
• There is moisture in the molder parts.
  • Specify the parts to be “dry as molded” and dry the parts by heating prior to welding.

Probable Causes and Solutions:

• A mold release agent is used.
  • Clean the mating surface of weld interface. If a mold release agent is necessary, use a paintable/printable grade.
• There are incorrect part tolerances.
  • Tighten the part tolerances, check the part dimensions, and ensure correct molding conditions.
• There are cavity-to-cavity variations.
  • Ensure part dimensions and tolerances are within specification, check for cavity wear, ensure correct molding conditions, and perform a statistical study to see if a pattern develops with certain cavity combinations.
• The resign contains regrind or degraded plastic.
  • Consult with the molder, ensure correct molding conditions, reduce the percentage of regrind, ensure consistent percentage of regrind, or improve the quality or the regrind.
• There are fluctuations in the AC line voltage supplied to the generator.
  • You need to upgrade to a generator with line load regulation.
• There are fluctuations in the air line pressure.
  • Upgrade to iQ Servo welding system, upgrade to a system with electronic pressure regulation, add a surge tank with a check valve to the airline, and raise the compressor output pressure.
• The plastic’s filler content is too high.
  • Reduce the percentage of filler in the plastic, ensure correct molding conditions, or change the type of filler (e.g., from short to long glass fibers).
• The horn doesn’t fit the part correctly.
  • Check the part dimensions, check for cavity-to-cavity variations, or consult Dukane to modify existing horn.
• There is a lack of parallelism between the horn, part, and/or fixture.
  • Check for parallelism between the horn, check the horn/part fit, check the part/fixture fit, or level the fixture where necessary.
• The rigid fixture reflects vibratory energy.
  • Damp the energy by using Teflon. Neoprene, cork or urethane in the nest of the fixture.

Probable Causes and Solutions:

• The Energy director could be too large.
  • Reduce the size of the energy director and the gauge pressure and use an interrupted energy director.
• The Shear interference is too large.
  • Reduce the amount of interference.
• The primary weld parameter is too large.
  • Reduce the weld parameter.
• The amplitude setting is too high.
  • Reduce amplitude % or booster ratio.
• The amplitude is too high at the end of weld cycle.
  • Reduce the amplitude during the weld cycle and use Dynamic Hold Distance.
• The IQ Servo Weld Speed is too low.
  • Increase IQ Servo Weld Speed or use Melt Match® speed profiling.
• The Trigger Force is too high.
  • Reduce Trigger Force.
• There are Non-uniform joint dimensions.
  • Re-dimension the joint, redesign the joint to be a shear joint or a tongue-in-groove joint, and check the mold processing conditions.
• The part fit too tight.
  • Increase part to part spacing.

Probable Cause and Solution:

• The internal components are made of the same material.
  • Make sure the internal components are made out of a dissimilar resin, lubricate the internal parts, or consider using a higher frequency system.

Probable Cause and Solution:

• Excessive amplitude.    
  • Reduce the amplitude by changing to a lower gain booster or reduce amplitude percentage.
  • Use amplitude profiling.
• Excessive exposure to ultrasound.                        
  • Reduce the primary weld parameter.
  • Increase the amplitude by changing to a higher gain booster to decrease weld time.
  • Increase Servo controlled Infinity's or iQ Servo Weld Speed or use Melt-Match® speed profiling.
• Improper gate location/design or thin wall                 
  • Change gate placement.sections.                                                                      
  • Change the shape of the gate.
  • Add stiffening ribs to the part.
  • Increase the thickness of the material on the underside of the gate area.
  • Consider using a higher frequency system.
  • Consult Dukane for nodal plunger horn option.
• Horn design and/or its placement.
  • Check for the proper horn to part fit, change horn design if required.

Probable Causes and Solutions:

• The parts are not self-aligning.
  • Add a means of alignment (e.g., pins and sockets) to the mating part halves.
• There is improper support in the fixture.
  • Redesign the fixture for proper support.
• There is wall flexure.
  • Add ribs or gussets to the part and add a rigid gusset to unsupported sections in resilient fixtures.
• The joint design Is not properly dimensioned.
  • Re-dimension the parts.
• There is incorrect part tolerance/poor molding.
  • Tighten the part tolerance and ensure correct molding conditions.

Yes, the industrial HMI can be shut down at any time. It will not hurt the function of the machine or HMI.

The oil should be changed out every 10,000 hours or when it is discolored.

Tool ID in a Dukane machine is simple binary input to the machine through the tooling connector. By wiring 24 volts to the correct pins it is possible to give a tool a unique tool ID. In using this each time you plug in the tool the program associated with the tool will be pulled up in the PLC/HMI. So there is no chance to get the wrong weld parameters for a given application and no reason to set up parameters when you load the tooling.

This is the way you Zero the weight of the tool and the table. Allow you to know that the force you are developing is what you are putting on the part during weld. In some machines you enter the tool weight directly and the machine knows the weight of the table and subtracts both from the pressure in the system. The more accurate way to do this is called “Float the Table”. In this case you load the tooling and run a process of increasing pressure until the table moves. That is where the force to lift is zero. Then this pressure is subtracted from the force of the system.

See operation manual section 11. Main items listed below:

• Change air filter on 15 psig drop or every 2 years
• Check hydraulic fluid levels weekly
• Change hydraulic filter yearly
• Change hydraulic fluid every 10,000 hours or when discolored
• Grease all 8 zerk fittings on bearings once or twice a year. (grease only bearings rails do not need grease on them.

An un-balanced tool will not run linearly. It will start to move in a orbit form. This stresses the lamination carriers and the Coils. A balanced tool is the single most important thing you can do to make the machine last longer.

The bolts in all spring and lamination carriers must be used. The upper moving tool develops up to 208g’s. This means a 100 pound tool will dynamically produce 20,000 pounds + of dynamic load. Electrically we can see one bolt missing and the head to begin to run not in a desired mode. Multiple bolts missing will damage the machine and void a warranty.

Check top status bar on HMI to find out why it is not ready for cycle.

• Make sure back doors are closed
• Check all e-stops are cleared
• Make sure the machine is in auto mode
• Make sure machine is in home and “ready for cycle”
• Make sure all part presence switches are made.

Yes, we weld parts all the time that hold significant pressure without leaking. Example of some of these applications are Tail lamps, Intake Manifolds, Electronic modules, Toilet tanks, and many others

Yes you can use the Dukane Material compatibility chart available on the website to determine what materials are weldable to each other. Then you need to answer two more questions:

• Material must have similar melt processing temperatures within 20 degrees C of each other.
• Material melt flow must be within 4 of each other.

Hold pressure should not exceed weld pressure. In fact it is nice to reduce hold pressure by 10% or so. When a welder goes into hold mode you get “post weld collapse” and this is a thinning of the heat affected zone. This thinning is a reduction in weld strength. You need hold pressure but excessive pressure can yield a cold weld.

You need to calculate all the surface area of the top of the weld beads. Then multiply this area by 250 lbs / square inches of area. This is a good starting point it can vary by a lot based on application.

In general the marks are from the part moving in the nest (could be upper or lower nest or both). You need to increase weld pressure so the parts lock up in the nest better. This usually solves the problem. If not finding a way to lock the part on the tool may be required. The use of locators and return flanges in your part usually will work fine.

We need to be thinking pressure and amplitude. If you have a weld in an area where you do not want a weld you need to remove the pressure or remove the amplitude. Usually this means you need to clear the supporting nest in this area relieving any chance that pressure is applied to the area of unwanted weld. Only in rare occasions is it possible to reduce or eliminate the amplitude.

If possible, it is usually better to weld in melt down distance. This is the only closed loop welding method. You can change pressure, amplitude, and even surface area of weld part to part and still make the same distance giving you consistent welds.

Check the weld time of the machine. It is very probable that you have exceeded the maximum weld time. You will need to add more time or increase clamp pressure or amplitude to make distance in desired amount of time.

A melt map is usually done at 0.5mm or half the desired weld depth. By welding the part at minimum weld depth tearing the part and looking at all weld beads you will find areas of no weld. You would add shims to the tooling until you get around 80% of all areas welded. Then weld the part at full melt depth and check to see if you are making all critical characteristics of the part that are required.

Hold time, is a period of time after weld is completed where the head rings back down to center position and then part stays clamped in the nest until the molten plastic part solidifies. Generally accepted rule is if the parts welds in “X” seconds you need “1/2X” amount of hold time. If you are not cycle time constrained just make hold time equal to weld time.

What you need to think of are pressure and amplitude.

• Tools are usually segmented so as they can be shimmed.By adding a shim in the un-welded area, you increase the pressure in that area creating more weld.
• If when shim is added and then more shim is added and the un-welded area grows you could have a problem with amplitude. This usually means you have a weld bead 90 degrees to the direction of amplitude. Adding shims exacerbates the problem and reduces the relative motions between the parts. In this case you may need to remove shims and even lower the shim by cutting off the bottom of the detail. Most cases require the part to be changed so the wall is stiffer and does not move during welding.

Auto tune is the matching of the natural resonance of the head to the digital drive. When this matching of the frequency occurs, you get lowest possible power draw from the power supply. A small deviation of even 1Hz can mean a lot of lost power. This excess power will show up in your coils of the vibration head causing excessive heat which over time can damage the coils and or lamination carriers. An auto tune can and should be done at every change in tooling. It also can be done in between tooling changes. Dukane machines can be autotuned on a set number of cycles.