Products
- Ultrasonic Welding Products
  - Ultrasonic Welders
    - Infinity™ with Melt-Match®
    - P220 Ultrasonic Welder
  - Ultrasonic Film & Fabric Processing
  - Ultrasonic Cutting Solutions
  - 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
  - Infinity™ Ultrasonic Welding: Leading the Way in a Post-pneumatic WorldDukane ultrasonic welders deliver precision, speed, and reliability for plastic joining. Explore our models and request a quote today.Get full control with the Infinity™ Servo Welder with Melt-Match® — precise 100% digital ultrasonic welding for thermoplastics & metals. Request quote!P220 Pneumatic Ultrasonic Welder: robust design, multiple weld-modes, consistent & repeatable. Request a quote & upgrade your welds now!Dukane ultrasonic systems deliver fast, clean film & fabric processing. Improve efficiency and quality—explore solutions and request info today.Dukane ultrasonic sealing machines deliver clean, precise seals for film & fabric. Enhance efficiency and quality—explore solutions today.Dukane ultrasonic rotary bonding systems ensure fast, durable bonds for film & fabric. Improve quality and efficiency—learn more today.Dukane ultrasonic fabric & film systems deliver clean, reliable bonding and sealing. Boost production quality and efficiency—explore solutions today.Dukane’s iQ Servo Cut & Seal system combines ultrasonic sealing & cutting for precise film and fabric processing. Explore it and request a quote todayDukane ultrasonic cutting solutions deliver precision trimming and clean cuts. Explore options and request your quote today to upgrade your process.Cut rubber, composites & aerospace materials cleanly with Dukane’s industrial ultrasonic cutting: replaceable blades, 20-40 kHz, rugged design. Request quote!Dukane ultrasonic rubber cutting delivers precise, clean cuts without heat damage. Learn about our 20-40 kHz systems and request a quote today.Dukane ultrasonic food cutting: clean, precise cuts in cheese, confections & layered foods. Stick-free, less waste, higher throughput. Contact us today!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.Dukane’s iQ AIM Ultrasonic Generator offers weld modes by Distance, Energy, Power, Time & Continuous. Maximize flexibility—request a quote today.Quick and Easy integration in automation systems with Ultrasonic Generator. Seamlessly fits your control panel either vertically or horizontally and an intelligent cable management setup ensures a clean look and finishIntegrate Dukane’s iQ Auto-Plus with patented MPC easily into automation systems. Save space, cut cabling, and streamline production—request a quote. Dukane’s iQ AL-E Ultrasonic Generator with Trigger by Power ensures precise starts & repeatable welds. Boost accuracy—request a quote today.Dukane’s patented Multi-Point Control (MPC) simplifies automation with reduced cabling and cleaner integration. Explore benefits and request a quote.Design your ideal ultrasonic welder with Dukane’s custom solutions. Get a system built to your specs—explore and request a quote today.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 placeManufacturers need flexible automation to stay competitive. Robot work cells bring precision and control to ultrasonic welding applications.Patented MPC ultrasonic generators control multiple probes, cut capital costs, and simplify programming for efficient welding automation.Patented MPC ultrasonic generators manage multiple probes, reduce capital costs, and streamline programming in rotary welding work cells.HP and PG ultrasonic hand probes feature ergonomic soft grips and attachments for counterbalance devices, ensuring comfort and precision.Lightweight iQ handheld welder with soft-grip probes, portable design, and audible alerts for operator-friendly ultrasonic welding.iQLinQ™ enables automation-ready ultrasonic welding by connecting generators with automated systems through a proprietary protocol.Rotary horns deliver continuous high power for faster, consistent sealing. Focused energy and flywheel effect boost speed and seal integrityUltrasonic food processing uses a vibrating knife with a near-frictionless surface, reducing buildup and ensuring cleaner, precise cuts.Titanium horns offer excellent acoustic properties, strong fatigue resistance, and surface hardness, making them the preferred ultrasonic tooling.The iQ EZ Stapler is a compact ultrasonic module for blister and clamshell packaging, foot-switch activated for fast, hands-free welding.Talk with an expert, contact us today. We're always ready to help.
- Laser Plastic Welding System
- Heat Staking with Infinity Thermal
- Vibration Welding
  - 5000 Series
  - VW 6000 Series with Melt-Match®
  - Dukane vibration welding systems deliver clean, fast, high-quality joints and are ideal for efficiently joining large plastic parts.VW 5000 Series vibration welders set the benchmark for quality, precision, and reliability in ultrasonic plastic welding applications.VW5300 vibration welder offers a smaller footprint for welding small parts, delivering efficient, precise, and high-quality plastic welds.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.VW5700 vibration welder offers real-time graphing and built-in logic control for easier monitoring and troubleshooting. Contact Dukane today.VW5700LPT vibration welder handles parts up to 950x510 mm with a heavy-duty flame-cut bridge for stability. Contact Dukane to learn more.VW5900 vibration welder assembles large parts up to 1550x550mm with a robust frame and stable bridge design. Contact Dukane to learn more.VW5960LPT vibration welder handles wide parts up to 950x510mm with a heavy-duty bridge for stability. Contact Dukane today to learn more.This vibration welder offers the industry’s largest table with a 25% smaller footprint than current models. Contact Dukane to learn more today.Talk with an expert, contact us today. We're always ready to help.
- Spin Welders
  - Servo Weld ™ Plus Spin Welder
  - Dukane spin welders deliver strong, precise plastic welds with fast cycle times and durable design. Contact Dukane today to improve production.Servo Weld Plus spin welder uses dual servo motors for precise, accurate plastic assembly welds. Contact Dukane today to enhance your productionTalk 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
  - ERW- Electromagnetic Resistance Welding
  - Eliminate particulate from your welding process and produce cleaner, stronger plastic parts with better aesthetics with latest welding technologies.Dukane’s patented hot gas welding delivers particle-free, oxidation-free welds for superior quality. Contact us today to learn more.TH3 Thermal Hybrid offers Infrared, Hot Plate & Hot Gas welding in one configurable system. Switch processes fast—contact Dukane today. Dukane rotary IR welder joins small parts up to 200x250mm with non-contact precision and cycle times as fast as 8 seconds. Contact us todayTwo-Phase Thermoforming assembles thermoplastics, plastic-plastic, and plastic-metal with ease. Contact Dukane today to optimize production.Talk with an expert, contact us today. We're always ready to help.
- Hot Plate Welders
  - Hot Plate Welder - TH3
  - TH3 hybrid welder switches between Hot Plate, Hot Gas & Infrared tools fast, saving costs on future programs. Contact Dukane to learn more today.TH3 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.Get efficient, reliable sealing of non-woven materials with Dukane's Rotary Ultrasonic Solutions. Learn more and request a quote today.Soniseal™ WD bonders feature full wash-down capability—no bagging required. Keep them on your machine during cleaning. Learn more today.Rotary horns deliver continuous high power for faster, consistent sealing. Improve packaging efficiency—explore Soniseal™ 40 UL today.Aurizon® Sonisolution™ RS boosts speed, quality, and efficiency while reducing costs. Integrate high-power ultrasonic tech—learn more today.Boost packaging productivity and cut costs with Aurizon® Soniseal™ 40 Series. Patented rotary ultrasonic tech delivers proven performance—learn more.Seal non-woven materials efficiently with Dukane’s Rotary Ultrasonic Solutions. Ensure reliable results—explore our sealing technology today.Dukane’s patented ultrasonic process bonds elastic between nonwoven layers with precision. Improve product design—learn more today.Attach elastic strands directly to nonwovens with Dukane’s ultrasonic tech. Eliminate costly adhesives—boost efficiency and learn more today.Join and attach nonwoven materials without glue using Dukane’s patented ultrasonic technology. Enhance efficiency—explore solutions today.Dukane’s ultrasonic lamination tacks layers with precision while preserving web functionality like absorbency. Improve performance—learn more.Dukane’s Ultrasonic Cut & Seal delivers versatile solutions for nonwovens across industries. Ensure precision and efficiency—learn more today.Talk with an expert, contact us today. We're always ready to help.
Markets We Serve
- Automotive
  - Ultrasonic Tire Cutting
  - Dukane’s plastic welding solutions built for the automotive industry — from concept to launch with quality, efficiency & compliance. Contact us to get started!Talk with an expert, contact us today. We're always ready to help.
- Medical
  - Diabetes Care
  - Critical Hospital Care
  - Advanced Home Care
  - Wearables & PPE
  - Dukane delivers precision plastic joining & welding solutions for medical devices — ultrasonics, laser, spin, hot gas & more. Ensure compliance, quality & scale. Talk to our experts now!Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Dukane is a leading provider of ultrasonic welding technology and solutions for the in vitro diagnostics (IVD) industry.Talk with an expert, contact us today. We're always ready to help.
- Electronics
- Non-woven & Hygiene
  - Full Panel Elastic With Ultrasonic Bonding
  - Face Mask Construction
  - Disposable Gown Construction
  - Boost efficiency & cut costs with Dukane’s high-speed ultrasonic bonding & cutting for nonwoven materials. Reduce adhesives, improve seam quality. Contact us today!Our 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
  - SynQro Spout Sealing Module
  - Ultrasonic Sealing & Cutting with patented Quadro
  - Boost packaging performance with Dukane’s ultrasonic sealing & cutting—hermetic or peelable seals, no adhesives, digitally controlled. Get a quote today!Patented SynQro technology enables dialogue between two ultrasonic generators to drive energy through two sonotrodes instead of one sonotrode and anvil.Patented Quadro™ is the next evolution in ultrasonic sealing technology, engineered to deliver unmatched precision, speed, and seal integrity for today's high-performance packaging demands. Talk with an expert, contact us today. We're always ready to help.
- Automation
- Ultrasonic Cutting
  - Ultrasonic Industrial Cutting
  - Ultrasonic Tire Cutting
  - Ultrasonic Food Cutting
  - Achieve clean, precise cuts in thermoplastics, textile & non-woven materials with Dukane’s ultrasonic cutting systems. Automate now — contact us today!Talk with an expert, contact us today. We're always ready to help.
Company
- About Us
- Locations
  - Global Headquarters, St. Charles, IL
  - Dukane Center of Excellence – Kimberly, Wisconsin
  - Dukane Film & Fabric Technical Center - Georgia, USA
  - Dukane Automotive Technical Center - Michigan, USA
  - Dukane Mexico
  - Dukane Czech
  - Dukane has led plastic welding worldwide. Find a location near you and connect with us for trusted welding solutions todayDukane Global Headquarters is conveniently located in St. Charles, IL. Dukane is one of the largest employer in the tri-cities area of Chicago’s Western Suburb. St. Charles, Batavia and Geneva make up the tri-cities area.Discover Dukane’s Kimberly, Wisconsin Center of Excellence, advancing ultrasonic bonding and sustainable solutions for hygiene, nonwoven, and packaging industries.Fabric & film applications often call for innovative and specialized solutions. That’s why we have a professionally staffed facility dedicated exclusively to fulfilling those needs.The Automotive Technical center supports the automotive industry in North America and around the world.This center provides cost effective plastic welding solutions, instant customer service and expedited delivery, to customers in Latin American countries.The local engineers, tool designers and tech staff at the Czech Republic European Technical Center provide fast delivery, better solutions and lower costs.Talk with an expert, contact us today. We're always ready to help.
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- Our Processes
  - Ultrasonic Plastic Welding
  - Vibration Welding
  - Laser Welding
  - Spin Welding
  - Infrared Welding
  - Hot Plate Welding
  - Ultrasonic Food Cutting
  - Ultrasonic Film & Fabric Processing
  - Learn how plastic welding bonds thermoplastics through pressing, heating, and cooling. Explore our process guide to start your project today.Ultrasonic 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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The Science of Ultrasonic Welding

Name: The Science of Ultrasonic Welding
Uploaded: 10/28/2025 12:00:00 AM

Which Materials Are Best for Ultrasonic Welding? This comprehensive guide covers essential topics related to selecting the right materials for ultrasonic welding. Learn about valuable insights into polymers, thermoplastics, material compatibility, and more!

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The Science of Ultrasonic Welding

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