Industries and Markets Served: 

Defense, Consumer Products, Industrial Components, Radio Chemistry, Mining, Petroleum, Loss Prevention and Testing & Analysis.  See About Us.

Expectations Met: 
Our customers expect fair pricing, exceptional quality, technical competence and reliability. Send a Quote Request to experience what over 30 years of manufacturing excellence offers.

Ultrasonic Welding

Mega Corporation provides plastic ultrasonic welding services as both a secondary operation to injection molded plastics parts, and as a custom service to customers needing only ultrasonic welding. Our expertise in designing custom horns and fixtures, along with sophisticated ultrasonic welding machinery, allows us to deliver the best solutions in sonic welding.
Contact us for a quote on our ultrasonic welding services. Email or call 847-985-1900 Ext 11. You may also request a quote by following the link to our Quote Request page and completing the Comments section at the bottom. If what you are searching for is not here, we can design and manufacture it for you.

A Description of the Ultrasonic Welding Process

In ultrasonic welding, high-frequency vibrations generate heat at the interface of the parts to be joined, melting the plastic Ultrasonic welded insertand creating a strong bond. The technique is fast, efficient, non-contaminating and requires no consumables. It produces a clean weld site with highly uniform joint quality, providing exceptional performance, consistency, and reliability. Easily integrated into automated systems, ultrasonic welding can be readily customized to fit exact specifications of welded parts. Ultrasonic welding is well suited for assembling parts with delicate internal electronic components and can be used for ultrasonic insertion, ultrasonic staking, stud welding, degating, or spot welding.

Ultrasonic assembly is accomplished by converting high frequency electrical energy into high frequency mechanical motion. That mechanical motion, along with applied force, creates frictional heat at the plastic components’ mating surfaces (joint area) so the plastic material will melt and form a molecular bond between the parts. Standard 50 or 60 Hertz AC line voltage is supplied to the generator (power supply) and converted to 15,000 or 30,000 Hertz (i.e., 15 kHz or 30 kHz) AC electrical energy. This high frequency electrical energy is connected to a piezoelectric transducer (converter), which changes the electrical energy into mechanical vibrations. These vibrations, when applied to a part under force, will create frictional heat and cause the plastic to melt at the joint area. As the plastic cools, a homogeneous molecular bond is formed between the components.

Ultrasonic welding is the most common application of ultrasonic assembly. In welding, the horn is brought into contact with one of the workpieces, pressure is applied and vibrating ultrasonic energy travels through the material, generating frictional heat at the joint area between the two parts. The plastic material melts and flows between the two part surfaces. When the vibrations stop, the plastic solidifies and the two workpieces are bonded together. 


 Ultrasonic Assembly

 Ultransonic Forming

 Ultrasonic Insert