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6 articles
Appliance housings are large plastic parts with high appearance standards, accumulated tolerance and output pressure. What each constraint costs, and where the trade-offs are.
Sealed parts are judged on leakage, and a joint strong enough to pass a pull test may still leak. How sealing work differs from structural welding.
Three common methods, three ranges of application. Ultrasonic is solid-state and suits dissimilar and highly conductive metals; resistance is simple; laser is fast.
Adhesive introduces a foreign substance, with residue, biocompatibility and cure control to manage. An ultrasonic weld is the parent material itself.
Electrification pushes harnesses to higher voltage, higher current and more copper-to-aluminium joints, while OEMs demand per-part process data. Both favour welding.
Battery tabs are thin, soft and conductive; the process must add almost no heat, keep joint resistance low, and record every weld. Why solid-state joining fits.
