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91 articles

2026-09-09

Ultrasonic Welding of Busbars and Large Conductors

Busbars and heavy cable in new energy and storage demand far more power, force and amplitude than ordinary harness work. Selection constraints, copper versus aluminium, oxide.

Welding Stacks of Foil: Getting Through Dozens of Layers at Once

Technical

2026-09-09

Welding Stacks of Foil: Getting Through Dozens of Layers at Once

Battery tabs and capacitor leads require dozens of foil layers joined in one operation. Energy attenuates downward, trapped air prevents bonding, and foil cannot take overload.

Knurled Tooling in Metal Welding: Grip Comes First

Technical

2026-09-09

Knurled Tooling in Metal Welding: Grip Comes First

Metal ultrasonic welding relies on lateral shear to break up oxide and form a solid-state bond — and that shear only reaches the work if the knurl grips. Wear is the usual culprit.

Regrind, Pigment and Flame Retardant: Change the Formula, Redo the Parameters

Technical

2026-09-09

Regrind, Pigment and Flame Retardant: Change the Formula, Redo the Parameters

Within the same grade, regrind ratio, pigment and flame retardant all change how a material welds. What each does, and what to verify when material or supplier changes.

PET and PBT: Same Family, Different Behaviour

Technical

2026-09-09

PET and PBT: Same Family, Different Behaviour

PET and PBT are both polyesters but crystallise at very different rates, so they behave differently under ultrasonic welding. Welding one to the other is not recommended.

Welding PMMA: Easy to Fuse, Easy to Mark

Technical

2026-09-09

Welding PMMA: Easy to Fuse, Easy to Mark

PMMA is amorphous and fuses readily. The difficulty is brittleness and appearance — notch sensitivity at corners, and a clear surface that magnifies every mark.

Welding POM: Slippery, Stiff and a Narrow Melting Range

Technical

2026-09-09

Welding POM: Slippery, Stiff and a Narrow Melting Range

POM has a low surface friction coefficient, a narrow melting range and high crystallinity, giving a narrower process window than most engineering plastics.

PC Parts That Weld Fine and Crack Days Later

Technical

2026-09-09

PC Parts That Weld Fine and Crack Days Later

Environmental stress cracking in PC needs residual stress and chemical contact together, so it always shows up late — good at inspection, cracked days later.

Why a Horn Has to Be Designed for the Job

Technical

2026-09-09

Why a Horn Has to Be Designed for the Job

A horn must match the part, resonate at the working frequency and keep amplitude uniform all at once. The trade-offs, including length, material and surface treatment.

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