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100 articles

2026-09-09

Ultrasonic Cutting Is Not Ultrasonic Welding

Both use ultrasonic vibration to opposite ends: welding joins, cutting separates. Tool geometry, energy distribution and support all differ.

Ultrasonic, Resistance or Laser: Choosing a Metal Joining Method

Industry

2026-09-09

Ultrasonic, Resistance or Laser: Choosing a Metal Joining Method

Three common methods, three ranges of application. Ultrasonic is solid-state and suits dissimilar and highly conductive metals; resistance is simple; laser is fast.

Three Typical Defects in Metal Ultrasonic Welding

Technical

2026-09-09

Three Typical Defects in Metal Ultrasonic Welding

Slipping, crush-through and material pick-up are the three defects most often seen. Each looks different and points to a different cause.

Ultrasonic Welding of Busbars and Large Conductors

Technical

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.

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