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Tag Archive: welding

  1. The Facts About Hot Plate Welding

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    What is Hot Plate Welding?

    Hot plate welding is a method of joining thermoplastic parts in a permanent, molecular, and frequently hermetic bond. During the process, a heated table called a platen is heated to a specific temperature. Next, the two joining surfaces are brought into contact with the platen for a precise amount of time in order for them to melt before being joined together. A proper hot plate welded joint will be just as strong, if not stronger, than other areas of the part.

    Almost any thermoplastic material can be joined using hot plate welding, which has led it to be a frequently chosen solution for numerous applications. In cases where uniform weld flash, hermetic seals, or multiple parts per cycle are necessary, hot plate welding is frequently chosen as the preferred method.

    What Is the Process of Hot Plate Welding?

    Hot plate welding is a direct thermal contact process that creates a clean joint. This process allows nearly any shaped part to be joined together while eliminating the need for glues, adhesives, and solvents. It can be performed horizontally or vertically, and it can be used with complex geometric shapes, curved surfaces, and internal walls.

    As mentioned above, hot plate welding utilizes a heated platen. Once heated to a specific temperature, the plastic parts that are being welded are pressed against the plate to melt and soften the joint interface. To complete the weld, the melted parts are immediately pressed together.

    Hot plate welding

    Hot plate welding is a very forgiving process where parts are bent or deformed due to the injection molding process. If parts are taken out of the mold at high temperatures, the contractions of the plastic while cooling can bend or deform the parts. In a hot plate welding process, the parts welded are pressed against a metal plate that has the desired shape. From there, the plastic melts and takes the form of the hot plate so any deformation is corrected for a perfect result. This is particularly useful as the parts get bigger because it is more difficult to maintain tight tolerances.

    With some type of plastics, the adherence of the melted plastic to the hot plate becomes a problem. To solve this the hot plate is sometimes coated with Teflon or other materials that prevent adherence. Another option is bringing the hot plate to a position very close to the part so that radiation from the plate can melt the material without actually touching it, thus not having the opportunity to adhere.

    In our machines, we analyze the size and shape of the part and include as many heat zones as needed on the heat plate to obtain a uniform melted surface on the plastic parts. Each heat zone has independent temperature control. Another feature is that the movements of the parts and the heat plate are servo-controlled giving the process precise dimensional control of the melted material surface and the final pressing position of the welded components. We can also make the heat plate horizontal or vertical depending on the characteristics of the parts to be welded. We have made machines with different welding plates in different positions that weld at the same time. This applies to parts like automotive intake ducts that have many PCVs ports and connections that need to be welded in different locations and orientations.

    When to Use Hot Plate Welding

    There are several welding methods to consider when joining plastics; however, there are certain circumstances where hot plate welding is the preferable solution. If you are working with large components, or if the product has a complex geometry, hot plate welding would be the most effective joining method. It’s also an excellent choice for applications that don’t tolerate loose particulate or applications requiring a high-strength or hermetic seal.

    In addition to these instances, many components can benefit from the low-stress, high-strength nature of hot plate welding. It is an effective method for small parts with simple geometries, and it is frequently used with injection-molded components. It is also ideal for joining plastic pipes in applications where a completely leak-proof seal is required.

    Hot Plate Welding Solutions from AMD

    Advanced Manufacturing Development (AMD) offers welding automation packages tailored to each customer’s exact specifications. Our knowledgeable engineering team can offer weld process recommendations that optimize your productivity and functionality. If your application involves plastic materials, our hot plate welding machines can provide a solution that fully meets your needs.

    AMD is located in Texas, where our team of over 100 engineers creates expert automation solutions. We deliver excellence in manufacturing and can provide customers with the best possible prices through the use of our Mexican manufacturing facility. For more information on the welding solutions we offer and how we can meet the needs of your application, please contact us today.

  2. Is Ultrasonic Welding Right For Your Application?

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    What is Ultrasonic Welding?

    Ultrasonic welding is a process for joining together thermoplastics and nonferrous metals. Workers carry out this process on ultrasonic welding machines, loading parts into the device automatically. Once loaded, an ultrasonic sonotrode produces high-frequency vibrations to gently melt the two pieces of material together. After finishing the process, the worker then removes the newly formed unit. More than one sonotrode may be used in this process depending on the size and shape of the components being welded.

    Advantages of Ultrasonic Welding

    Ultrasonic welding’s use of high-frequency vibration provides a safer alternative for joining materials together. Due to the lack of heat required for the process, it does not carry the risk of burning that a torch would. Ultrasonic welding keeps the welding precise by melting only the points necessary to create a near-seamless joint between the two parts.

    ultrasonic probe testing welding steel for defect inspection ; quality control or assurance ; industrial equipment background

    The ultrasonic welding machines used in these processes are exceptionally user-friendly, robust, and simple to maintain. The parts used on these machines are modular in design, allowing for easy integration and replacement in the event of malfunction. Spare parts are readily available and tested for quality, which significantly decreases equipment downtime and operation standstills.

    In terms of manufacturing, ultrasonic welding has many advantages in relation to automation. Ultrasonic welding machines have a high processing speed that prioritizes efficiency without compromising on the quality of finished products. Depending on the complexity of the weld, cycle times can easily reach up to 60 cycles per minute and beyond with individual welding times lasting between 80 and 450 milliseconds. Additionally, the lack of a warm-up period for an ultrasonic welding machine means less time spent waiting for a machine to be ready for use.

    When is Ultrasonic Welding Needed?

    The main use for automated ultrasonic welding is the joining of plastics, particularly for electronic connector assemblies and other high frequency/high energy applications. Ultrasonic welding is gentle enough to work with both harder plastics and more delicate materials like foam. This makes it possible to join together different parts that might otherwise be destroyed with other bonding methods. Additionally, assemblies involving soft metals or those with lower melting points can benefit as well, as the low temperature of ultrasonic welding is less likely to damage the material or cause it to undergo undesirable reactions.

    Learn More Today

    The uses and benefits of ultrasonic welding are quite numerous, offering a safe and simple way to join soft or rigid plastics and other materials such as foam and nonferrous metals. Ultrasonic welding machines are designed for quality output and easy upkeep, ensuring smooth operations with minimal downtime.

    Advanced Manufacturing Development is one of the premier companies providing made-to-order turnkey welding automation packages. We tailor each order to the needs of the customer, and we are able to make modifications to equipment and programming as desired, with features like touch screens, camera systems, and much more available upon request.

    For more information, or to get started on your automated ultrasonic welding solution, contact us today.


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