There is no other process that can match the benefits of ultrasonic welding when it comes to molding two similar plastic parts.

Ultrasonic welding is fast, clean, and very repeatable.

On the other hand, ultrasonic welding can also be loud, scuff the plastic surface, and cause stress failures in the application.

The basic principle of ultrasonic assembly is the conversion of standard 50/60 Hz power to 20 kHz or 40 kHz. The electrical energy travels through a converter, which then expands and contracts at the same frequency converting the electrical energy into high frequency mechanical vibration. This vibration is amplified by a booster and transferred to the the workpiece through a shaped tool called a horn. Parts being assembled are clamped together under moderate pressure, at which point ultrasonic vibrations force the parts to collide against each other at a preset frequency creating a molecular bond equal to or above the material strength of the parts.