Sonic Welding Services

Sonic welding is a process that securely bonds two similar materials by using sound waves to soften the materials and facilitate strong adhesion. This welding process can achieve bonds with a strength comparable to that of the raw materials, making it a valuable and reliable solution for joining two components. Sonic welding services are ideal for sealed or precision components, with advantages including:

Strong, reliable bonds
Fast, clean, and efficient process
Cost-effective assembly

SR Plastics offers sonic welding services to complement our high-volume plastic injection molding services, providing you with fully finished components from a single source. Contact us for more information or request a quote to get started on your custom project today!

Core Processes and Sonic Welding Services by SR Plastics

Joint Design and Engineering Support

SR Plastics is backed by a team of experts to ensure optimal design and engineering. Our specialists design energy directors (small triangular features that melt first) to initiate a strong weld and optimize joint geometry through options like shear joints, tongue-and-groove joints, and step joints. We carefully evaluate materials to ensure they’re compatible with ultrasonic bonding, and closely monitor the welding process to reduce weld flash, weak bonds, or cosmetic defects.

Quality Control and Testing

Sonic welding creates high-quality hermetic seals without the use of consumables. We ensure weld integrity through visual inspections for flash, cracks, or misalignment. Our quality control process monitoring evaluates amplitude, pressure, weld time, and energy to maintain quality before, during, and after welding. All of our components are manufactured to AS9100 & ISO9001 compliance standards.

Production and Assembly Services

Our sonic welding services can be performed for both low-volume prototyping and testing as well as high-volume automated or semi-automated welding. Additionally, welding can be integrated with various secondary services or post-molding operations such as trimming, inspection, and packaging to deliver a complete assembly.

Custom Tooling and Fixture Fabrication

We design and manufacture custom nests, horns, and fixtures fully in-house, and perform tooling maintenance and lifecycle management to maintain high quality. We go the extra mile to verify precision alignment and ensure consistent weld quality for all components.

Benefits of Sonic Welding Plastics

Sonic welding is ideal for sealed or precision components, as it creates high-strength bonds and ensures consistent, clean joints between two different materials. There are several advantages of sonic welding plastics, including but not limited to:

Strong, reliable bonds: Sonic welding creates molecular-level fusion between parts, and is often stronger than adhesive or mechanical fastening.
Fast, clean, and efficient process: The welding process occurs in fractions of a second and does not require any additional materials like solvents or glues.
Cost-effective assembly: Sonic welding reduces part count and eliminates consumables like adhesives, lowering costs and supporting automation for high-volume production.

Sonic welding can also be used to attach metal inserts during the injection molding process, generating a reliable bond between both components.

Contact SR Plastics Today for Custom Sonic Welding Services

SR Plastic offers ultrasonic plastic welding services to provide a complete assembly solution that enhances product strength, consistency, and manufacturability. Get the custom plastic injection molded components you need, all under one roof.