Ultrasonic vibratory energy is used in several distinct assembly and finishing techniques as described below:

A . Welding

The process of generating melt at the mating surfaces of two thermoplastic parts. When ultrasonic vibrations stop, the molten material solidifies and a weld is achieved. The resultant joint strength approaches that of the parent material; with proper part and joint design, hermetic seals are possible. Ultrasonic welding allows fast, clean assembly without the use of consumables.

B . Staking

The process of melting and reforming a thermoplastic stud to mechanically lock a dissimilar material in place. Short cycle times, tight assemblies, good appearance of final assembly, and elimination of consumables are possible with this technique.

C . Inserting

Embedding a metal component (such as a threaded insert) in a preformed hole in a thermoplastic part. High strength, reduced moulding cycles and rapid installation with no stress build-up are some of the advantages.

D . Swaging/Forming

Mechanically capturing another component of an assembly by ultrasonically melting and reforming a ridge of plastic or reforming plastic tubing or other extruded parts. Advantages of this method include speed of processing, less stress build-up, good appearance, and the ability to overcome material memory.

E . Spot Welding

An assembly technique for joining two thermoplastic components at localised points without the necessity for preformed holes or an energy director. Spot welding produces a strong structural weld and is particularly suitable for large parts, sheets of extruded or cast thermoplastic, and parts with complicated geometry and hard-to-reach joining surfaces.

F . Slitting

The use of ultrasonic energy to slit and edge-seal knitted, woven and non-woven thermoplastic materials. Smooth, sealed edges that will not unravel are possible with this method. There is no "bead" or build-up of thickness on the slit edge to add bulk to rolled materials.

G . Textile/Film Sealing

The use of ultrasonic energy to join thin thermoplastic materials. Clear, pressure-tight seals in films, and neat, localised welds in textiles may be accomplished. Simultaneous cutting and sealing is also possible. A variety of patterned anvils are available to provide decorative and functional "stitch" patterns.