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91 articles

2026-09-10

Non-Painted Metallic Resins: Pigment Orientation Decides Whether the Joint Shows

Aluminium flake and pearlescent pigments reflect by orientation, and any melt flow disturbs that orientation, leaving a colour difference near the joint. The answer lies in structure and energy, not in fine-tuning parameters.

Textured Surfaces and Overmoulded Soft Touch: Where to Put the Load

Technical

2026-09-10

Textured Surfaces and Overmoulded Soft Touch: Where to Put the Load

A flattened grain does not come back and a mark in soft overmould does not either. On both, the answer is moving the horn load off the cosmetic surface and letting the fixture carry the force.

Choosing a Leak Test Method and Setting the Criterion

Technical

2026-09-10

Choosing a Leak Test Method and Setting the Criterion

Pressure decay, tracer gas and water immersion differ by orders of magnitude in sensitivity. Work out the leak rate the product can tolerate first, then choose the method — not the other way round.

Turning an IP Rating Into a Welding Process

Technical

2026-09-10

Turning an IP Rating Into a Welding Process

The two digits of an IP code cover dust and water, with the test conditions defined in IEC 60529. Translating the rating into required weld continuity and a leak criterion is what process engineering has to do.

Technical

2026-09-10

Tight at Despatch, Tight a Year Later?

Thermal cycling, vibration, media and damp heat degrade marginal joints. Residual stress is the hidden variable, and validation has to include retesting after ageing.

Can a Wall of a Few Tenths Still Be Welded

Technical

2026-09-10

Can a Wall of a Few Tenths Still Be Welded

Yes, but the director becomes too small for the tool to hold. The route for very thin walls is usually not a smaller joint but a change to shear, spot or rotary welding.

Technical

2026-09-10

When the Joint Is Not on One Plane

Curved, stepped or multi-level joints need the horn to touch every face at once. The real constraint is whether amplitude stays uniform across that surface.

Millimetre-Scale Parts: Small Enough Becomes Hard Again

Technical

2026-09-10

Millimetre-Scale Parts: Small Enough Becomes Hard Again

A small part means a small energy window, tight location tolerance and little room for joint geometry. Frequency goes up, and fixturing and handling become the main difficulty.

Technical

2026-09-10

Welding a Joint Over a Metre Long

One horn cannot hold amplitude uniform over that length. The answers are zoned drive, sequential sections, or a different process — not a bigger horn.

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