High-gain 'composite' ultrasonic horn

Our customer for this project had been individually fixing tabs onto a primary moulding, but as product sales were exceeding manufacturing throughput the project called for the fastest method of fixing multiple tabs in one process. As the material was semi-crystalline, the challenge was to produce an ultrasonic tool that would provide sufficient amplitude to the joint area. For such materials, a common block horn could not have achieved a quality weld.

Consonic successfully designed and manufactured a high-gain 'composite' ultrasonic horn which readily produced the necessary amplitude to weld 6 tabs in one shot, thus increasing throughput six-fold. This customer then upgraded their 10 year old analogue ultrasonic welder to a fully digital Branson 2000 series system, which enabled far greater control of the joining process and quality.