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    Ultrasonic welding – efficient joining technology for plastics

What is ultrasonic welding?

In plastic ultrasonic welding, thermoplastic workpieces are joined within 0.2 to 2 seconds by high-frequency vibrations – without additional adhesives, energy-efficiently and reliably for series production. The high-frequency mechanical vibrations range from 20 to 70 kHz and are controlled by a sonotrode. Precise energy transfer and frictional heat create the bond exactly where it is needed in the joining zone – ideal for delicate or complex geometries. The result is a permanent welded joint without additives. 

A particular advantage of ultrasonic welding is that the bond is created purely by joining technology, without the use of chemical additives. This ensures stable, tight and durable weld seams, even with demanding geometries. 

Typical examples of applications for the ultrasonic welding process are: 

Housing parts with complex geometries 
Functional elements such as valves, flaps and filters
Components suitable for series production for technical applications.

Which industries use ultrasonic welding?

Ultrasonic welding of plastics is used in numerous industries:

  • Automotive: sensor holders, light housings, ventilation components, etc.
  • Medical technology: filters, diagnostic housings, disposable products, etc.
  • Electronics: connectors, displays, housing closures, etc.
  • Consumer goods & packaging: flaps, housings, containers, can closures, etc.

Precise, clean and economical – with the ultrasonic welding process, we offer you a modern solution for high-strength plastic joints. As a German quality manufacturer, Plastro Mayer accompanies you from the initial idea to the finished welded joint – competently, flexibly and in accordance with the highest quality standards.

Ultrasonic welding of plastics - Focus on thermoplastic joints

Ultrasonic welding of plastics offers an efficient, precise and reliable method for joining thermoplastic components. The most suitable materials are: 

  • ABS (acrylonitrile butadiene styrene)
  • PP (polypropylene)
  • PC (polycarbonate)

Other weldable thermoplastics include PA (polyamide), PMMA (acrylic glass) and PE (polyethylene), whereby the choice of material depends on the application and the material pairing.

These plastics are characterised by excellent processability, efficient welding processes and high strength in the joint zone.

Overview of the advantages of ultrsonic welding Processes

Why should you use ultrasonic welding for your project? It's simple: it is one of the most efficient and precise welding processes in modern plastics processing. It combines economic, technical and ecological advantages, making it ideal for the series production of complex plastic components. 

Here's why this technology is worthwhile for your company: 

Efficiency: 

  • Welding time: 0.2 - 2 seconds
  • Energy efficiency thanks to short process times
  • Suitable for automation for high quantities 

Quality: 

  • Clean weld seam without residues around the joint zone
  • High strength and tightness 
  • Precise connections even with complex geometries

Cost-effectiveness: 

  • No adhesives or solvents required 
  • Minimal material usage
  • Short cycle times for series production 

Process reliability:

  • Digital control for consistent quality
  • Reproducible results
  • Integrated quality control possible.

Ultrasonic welding process at Plastro Mayer

A successful project begins with structured planning. At Plastro Mayer, we accompany you from the initial concept to series production – professionally, efficiently and with the highest quality standards. As a German quality manufacturer of injection moulding and cable solutions, we offer you a comprehensive range of services. 

This is how your project, including ultrasonic welding, will proceed with us:

  1. Requirements analysis: Definition of project goals, material requirements and component geometries in joint consultation.
  2. Feasibility study: Technical evaluation of vibration input, material pairing and cycle time optimisation.
  3. Prototyping & sampling: Creation of initial samples for realistic simulation of the welding process. 
  4. Series production: Injection moulding and ultrasonic welding in modern facilities. On request, including complete assembly of the final product.
  5. Quality assurance: Integrated testing processes and complete documentation.

Our focus is on industry-specific solutions. We implement customised concepts for the automotive industry, medical technology, the consumer goods industry and the electrical industry. You receive everything for your project from a single source – from injection moulding to final device assembly. This includes ultrasonic welding and the desired injection moulding post-processing. You benefit from end-to-end processes, short communication channels and high delivery reliability. Our many years of experience and numerous references speak for themselves.

Would you like to find out more or start your project right away? Then request your personal consultation now by phone or using the contact form. We will check the feasibility of your idea free of charge.

FAQ's Ultraschallschweißen

Is ultrasonic welding suitable for joining thick materials?
Ultrasonic welding is primarily designed for thin-walled thermoplastic parts. However, the process reaches its physical limits with thicker materials, as the high-frequency vibrations do not penetrate deep enough into the joining zone to create a uniform welded joint between the workpieces. However, through: • specially adapted sonotrodes, • optimised process parameters and • targeted component design it is also possible to achieve thicker wall thicknesses using the ultrasonic welding process.
What are the advantages of ultrasonic technology compared to other joining technologies?
Ultrasonic welding of plastics offers a number of clear advantages over other joining technologies such as gluing, screwing or heating element welding: • Speed: The connection is made in milliseconds. • Cleanliness: No additives such as adhesives or solvents are required. • Cleanliness: No residues are produced and no post-processing is necessary. • Energy efficiency: Energy is only applied at specific points. • Process reliability: Digital control for consistent quality • Process automation: The optimal solution for automated series production with high quantities.
How long is the welding time for ultrasonic welding?
The actual welding time for ultrasonic welding is extremely short, typically between 0.2 and 2 seconds. The exact duration depends on: • Material and component geometry • Welding surface size • Desired joint quality.
Which plastics can be processed using ultrasound?
Ultrasonic welding is particularly suitable for joining thermoplastics reliably and precisely. Materials such as the following are particularly well suited for welding • ABS (acrylonitrile butadiene styrene) • PP (polypropylene) • PC (polycarbonate) Other thermoplastics: PA, PMMA, PE – depending on the material pairing and application. Crucial: Compatible physical properties (melting temperature, elasticity, acoustic properties).
Can different plastics be joined using ultrasonic welding?
Das Ultraschallverschweißen verschiedener Kunststoffe ist grundsätzlich möglich – allerdings nur unter bestimmten Voraussetzungen. Erforderliche Bedingungen sind: • ähnliche Schmelztemperaturen, • kompatible Elastizitätseigenschaften und • abgestimmte akustische Eigenschaften. In der Praxis bedeutet das: Nicht alle Materialkombinationen sind miteinander verschweißbar. Doch bei kompatiblen Werkstoffen lässt sich eine stabile und langlebige Schweißverbindung realisieren.Ultrasonic welding of different plastics is possible in principle – but only under certain conditions. The necessary conditions are: • similar melting temperatures, • compatible elasticity properties and • matched acoustic properties. In practice, this means that not all material combinations can be welded together. However, stable and durable welded joints can be achieved with compatible materials.
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