Thin Wall Ultrasonic Bonding Technology for Automotive

A newly patented ultrasonic bonding technology has been developed by Dukane for thin-wall welding. The new Ultrasonic Thin Wall welding system is most commonly used in the automotive vertical, particularly for welding applications of PP to PP TD25 painted parts in such areas as bumpers, spoilers, rocker panels, and wheel arches.

According to the company, this bonding technology specializes in joining PDC brackets, masks, or stiffeners onto a range of automotive components such as bumpers, wheel arches, spoilers, and rockers with unparalleled precision and strength and without any read or mark on the painted surface. The patented 50 kHz ultrasonic welding technology, coupled with a servo actuator, is said to deliver optimal results for painted part thicknesses ranging from 2.2 mm to 2.7 mm, ensuring seamless integration and exceptional performance. This new technology sits at the forefront of ultrasonic innovation, allowing effortless welding of components and guaranteeing no read, visible marks, or signs are left behind on the painted surface. Key Benefits of Dukane’s Thin Wall Ultrasonic Welding Technology include:

• Reliability: With years of successful implementation in many different production environments, Dukane’s technology provides unmatched reliability.
• Exceptionally Strong Welds: Dukane’s welds exhibit impressive strength, with PDC connections enduring pull-out forces of up to 350N.
• Paint Compatibility: This new technology seamlessly welds painted surfaces, eliminating concerns about inner bumper paint affecting the welding process.
• No Read or Marking: Extensive testing on various painted bumper thicknesses confirms zero marking, even with sensor holes or thicker paint layers.
• Integration Flexibility: Whether integrated into existing assembly lines or deployed in standalone machines, this new technology offers easy integration.

Other key features include the system’s use of a high-grain full-wave or 1.5-wave horn with an iQ Auto-Plus Ultrasonic Generator and 600W probe for optimal weld strength and precision. The system’s patented “Trigger by Power” technology ensures controlled speed throughout the weld, reducing the risk of surface imperfections. Collapse distance is strategically smaller than the part’s thickness, guaranteeing a seamless finish. Finally, complete servo module options (rotary linear servo or linear servo) are available for streamlined integration into manufacturing processes.