• Plastic Welding

    Plastic products cannot always be made in one piece. Design and tooling constraints sometimes make it more economical and/or advantageous to tool the product as two or more pieces. Post moulding joining of the parts provides a means of achieving an end solution  


    Which Method?

    The choice of which method of joining ultimately depends on the parts material, geometry and size, process capability, volume and cycle time desired. Other considerations such as capital costs will have a bearing on the choice

    Ultrasonic Welding

    Branson Plastics Machinery

    Laser Welding

    Branson Plastics Machinery

    Ultrasonic Welding uses high frequency energy which is transmitted through the parts to melt and bond thermoplastic materials. This technique is fast, efficient, non-contaminating and requires no consumables. In addition to welding, ultrasonic processes can be used to insert, stake, stud weld, degate, and spot weld thermoplastics as well as seal, slit, and laminate thermoplastic films and fabrics.

    Laser IRAM is based on the idea of passing light/laser radiation through one plastic component and designing the second component to absorb the laser light. This absorption results in heating and melting of the interface and with the application of a controlled clamp force, the parts are joined. The major breakthrough of IRAM technology is the ability to heat the entire welding surface simultaneously as compared to heating a single spot and moving the IR spot across the welding zone.

    Linear Vibration Welding

    Branson Plastics Machinery

    Orbital vibration welding

    Branson Plastics Machinery

    Linear vibration welding uses the frictional heat generated at the joint interface of the two parts to be welded to melt the plastic. The heat energy is achieved by moving one part relative to its mating piece under pressure through a given displacement or amplitude. Once the desired amount of melt has been achieved, the vibration is stopped, and the parts are held together under force for a short period of time, allowing the weld area to solidify.

    Orbital vibration welding is a friction welding process. In orbital vibration welding, the upper section is vibrated using constant velocity orbital motion – circular motion in all directions. This motion generates heat, which raises the plastic to its melting point. Once melting occurs, the motion is stopped, allowing the plastic to solidify into a permanent bond. Low clamping pressure results in minimum part distortion. Parts up to 10" in diameter may be orbital welded

    Spin Welding

    Branson Plastics Machinery

    Hot plate welding

    Branson Plastics Machinery

    Spin welding joins thermoplastic parts with a circular joint area by bringing the part interfaces together, under pressure, with a circular, spinning motion. One part is held stationary in a fixture, while the other is rotated against it under pressure. At least one section must be circular. The frictional heat that is generated causes the part interfaces to melt and fuse together, creating a strong, hermetic seal.

    Hot plate welding is a direct thermal welding technique that uses a heated platen to contact the mating surfaces of the parts to be assembled. This technique permits a wide latitude in designing parts with complex, irregular shapes – the joint can be curved in all planes, and welding of internal walls is possible. It is applicable to most thermoplastics, and is especially effective on semi-crystalline resins such as polyethylene and polypropylene. The process is suitable for parts up to 72" x 24" or multiple smaller parts.


    Typical Products made using the Welding Processes

    The welding processes above are used to make many diverse products, some examples of these are shown below or if you would like to see some of the welding techniques in action you can visit our Welding Techniques page

    Ultrasonic Welding Applications
    Linear Vibration Welding Applications

    Branson Plastics Machinery
    A selection of consumer articles which have been assembled with the
    assistance of Ultra-sonic Welding

    Branson Plastics Machinery
    Shows a selection of plastic Automotive parts which have
    been Linear Vibration Welded


    Orbital Welding Applications

    Welded Plastic

    Welded Plastic

    Iron

    Welded Plastic

    Welded Plastic

    Welded Plastic

    A selection of plastic components which have been Orbital Vibration Welded


    Spin Welding Applications

    Welded Plastic

    Welded Plastic

    Welded Plastic

    Welded Plastic

    Welded Plastic

    Welded Plastic

    A selection of components which have been Spin Welded


    Hot Plate Welding Applications


    Welded Plastic
    A selection of plastic components which have been Hot Plate Welded