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Medical Device Manufacturing

Ultrasonic welding

Ultrasonic Welding

Ultrasonic welding is whereby high-frequency ultrasonic acoustic vibrations are applied to two components being held together under pressure to create a solid-state weld. UW is commonly used for plastics and especially for joining dissimilar materials. In this process there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together.

LSO has Ultrasonic welding equipment onsite and is adept at developing the custom Sonotrode or "Horn" specific to the two components that will be bonded together. All UW systems possess these same components:

  • Press- applies pressure to the two components being welded
  • Nest- where the components are placed prior to the welding process
  • Ultrasonic Stack- consists of a converter or piezoelectric transducer, optional booster and a horn.
    • Converter- converts the electric signal into mechanical vibration
    • Booster-modifies the amplitude of the converter
    • Sonotrode or Horn- applies the mechanical vibration to the parts
  • Electronic Ultrasonic Generator- a US power supply delivering a high AC frequency (Typically 20, 30, 35 or 40 kHz)
  • Controller- controls the movement of the press

The use of Ultrasonic welding in the medical device industry is prevalent. This equipment is usually placed in a clean room so that contaminants are not introduced. LSO has produced a variety of components utilizing UW in our Class 10,000, including the following:

  • Textile type material for implant
  • Transdermal patches
  • Mesh based material for implant
  • Plastic casing housing electronics
  • Respiratory filters

Our engineering department looks forward to discussing your specific ultrasonic welding needs and developing your custom sonotrode.

Please contact us to discuss your specific needs and to receive a quotation for services in just a few days.