What Is Sonic Welding?
Basics of Sonic Welding
Sonic welding is when two materials are held in conjunction with one another in an ultrasonic press by a mechanical force without melting the base material. Ultra-high frequency sound waves/vibrations are applied into the materials with a sonotrode tool. This process utilizes mechanical vibrations that are higher than the hearing range. It typically takes only 0.2 seconds for the two thermoplastic parts to be welded together. The thickness of the materials determines whether two items can be jointly ultrasonically sealed.
Applications that often benefit from sonic welding include:
- Medical
- Military
- Packaging
- Electrical components
Specific Material Features
Sonic welding consists of bonding two dissimilar materials together through high-frequency acoustic vibrations and pressure. A thermoplastic material is necessary to achieve a bond with other fabrics, such as a hook bonded to a loop fabric. The final bond is stronger when the welded parts are the same material.
TPI Offers Sonic Welding for Medical Devices
TPI’s sonic welding experts are here to conjoin materials in certain applications with the goal of satisfying your needs. This type of welding is preferred over standard fabric welding because the process is faster and safer when bonding fabric materials. This sonic welding process requires less energy and has the added benefit of shorter cycle times and lower tooling costs, resulting in overall lower costs for our customers compared to competitive processes. Our team of experts will work closely with you in meeting your product requirements.
Some of our sonic welding projects include:
- Medical CPAP headgear
- Straps for military and law enforcement
- Patient transfer devices
We are here to exceed your project requirements and help you along the way in developing a quality prototype and product.
Looking for sonic welding services?
We work with medical device and OEM manufacturers as your single source for custom cutting, sewing, and sealing. Contact us at 800.588.8230 to get started on your project today!
