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How Ultrasonic Welding Works

03/02/15

Nails, glue, screws, thread. These are the most commonly seen forms of bonding, ones that require a sort of proverbial middle man to create the connection.

With ultrasonic welding, however, an industrial technique introduced in the 1940s, connections can be made without the need for additional adhesives or binding products.

Used on everything from medical devices to shoes (and our SS15 Ultrasonic Mac, seen above), ultrasonic welding uses high-frequency sound waves and pressure to bond material together with an unparalleled efficiency.

Okay, so how does this all work?

Friction, as anyone who’s ever made a fire by hand might know, causes heat. In ultrasonic welding, high-frequency sound causes intense vibrations in the two separate materials, rubbing them against one another until the temperature rises enough to bind the pieces together. 

Still don’t get it? Let’s take it step by step, using the Ultrasonic Mac as an example.

First, two separate pieces of fabric are placed in a fixture, connected by something called a horn, which will deliver the ultrasonic frequencies. To keep the fabric and the horn together, pressure is applied. With the connection established, the horn transmits ultrasonic vibrations to create heat. Voila. The fabric is now bonded together.

This now concludes your ultrasonic welding tutorial.