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Thermoplastic ultrasonic welding for material suitability guide

The process of ultrasonic welding of thermoplastic is achieved by applying a vibrating metal tool, also called ultrasonic sonotrode/hone at 90 degree to the stationary plastic object which then vibrate. When combined with pressure, friction produces heat ad melts the parts at the horn contact point, once cooled down a solid homogeneous weld between the two parts is achieved

Intended to help with ultrasonic welding of thermoplastic for your application, this plastic ultrasonic welding guide lists the most common unfilled grades of plastic available and their suitability for each style of ultrasonic welding, as a rule, stiffer materials are easier to weld and those with high melt temperature need more energy, to weld different materials, they need similar molecular structure, crystalline ones are only weldable to themselves

Material abbreviation in A or C			Close weld	Distant Weld	Insert	Spot Weld
Acetal Co/Homopolymer	POM	C	Good	Fair	Good	Fair
Acrylic	PMMA	A	Good	Fair	Good	Good
Acrylic-impact Modified	PMMA	A	Fair	Poor	Poor	Fair
Acrylonitrile Butadiene Styrene	ABS	A	Very Good	Good	Very Good	Very Good
Cellulose Acetate	CA/B/P	A	Poor	Unsuitable	Very Good	Poor
Polyamide 6 & 66 (Nylon)	PA6&66	C	Good	Fair	Good	Fair
Polycarbonate	PC	A	Good	Fair	Good	Good
Polycarbonate/ABS	PC/ABS	A	Good	Fair	Good	Good
Polyester-Thermoplastic	PBT/PET	C	Good	Fair	Good	Fair
Polyethylene-L/H density	LD/HDPE	C	Poor	Poor	Good	Good
Polyphenylene Oxide	PPO	A	Very Good	Good	Very Good	Very Good
Polyphenylene Sulphide	PPS	C	Good	Fair	Good	Fair
Polypropylene	PP	C	Fair-poor	Poor	Good	Very Good
Polystyrene-General Purpose	GPPS	A	Very Good	Very Good	Good	Fair
Polystyrene-High Impact	HIPS	A	Good	Poor	Good	Fair
Poly Vinyl Chloride-Flexible	PVC	A	Poor	Unsuitable	Unsuitable	Poor
Styrene Acrylonitrile	SAN/ASA	A	Very Good	Very Good	Good	Fair
A/Amorphous: Polymers with a random molecular chain structure, this and their wide softening temperature range enables them to soften gradually without solidifying quickly, thus making ultrasonic welding them easy
C/Crystalline: Polymers with an orderly molecular chain structure, this and their sharp melting and solidification points makes them absorb vibrations when solid, thus making ultrasonic welding them more difficult
Close welding: Ultrasonic welding where the horn is applied close to (<6.35mm) the assembly joint-good for welding materials whose low modulus of rigidity dampens vibration a short distance away from the horn
Distant welding: ultrasonic welding where the horn is applied away from (>6.35mm) to assembly joint, good for welding material those high modulus of elasticity propagates vibrations without dampening them
Inserting: ultrasonic embedding of metal components like inserts into performed holes in the molding, providing high strength and speed, no stress build up and reduced moulding cycles
Spot Welding: ultrasonic assembly of parts without premade holes or energy directors, good for large parts
Staking: melting and reforming a post on the moulding to mechanically lock dissimilar materials in place, provides short cycles, good appearance and tight assemblies

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