From process selection to production, we solve your most challenging plastic joining problems with proven methodologies and deep technical expertise.
Book Discovery CallChoose the optimal welding process and design parts for reliable joining from the start.
Tooling design and horn optimization consultation (guidance only; we do not design or manufacture tools/horns).
Analytical and experience-based approach to parameter development and optimization for consistent results.
Expert review of your validation protocols and documentation for regulatory compliance consultation.
Root cause analysis and corrective actions for welding failures and quality issues.
Smooth transition from prototype to production with ongoing technical support.
Deep knowledge across all major plastic welding technologies, with proven methodologies for each process. Included but not limited to:
small to medium parts within stringent geometry constraints
energy director, shear joint, tongue and groove
cracking of small features, incomplete or inconsistent welds, flash
softer polymers (PP, PE, TPU) may not be weldable in all configurations
precision applications
flat-to-flat, sometimes with a raised rib
incomplete penetration, degradation, uneven thickness
optical clarity is critical; may be inconsistent in semi-crystalline polymers
large parts where short cycle times are needed
raised ribs with or without flash traps
deformation (esp. thin walls), particulate
not suited for materials with low surface friction (e.g., PTFE)
large assemblies where vibration is not appropriate due to cost or geometry
butt joints, typically without flash traps
uneven heating, degradation, sticking to the tool
polymers with higher viscosity can be challenging
circular joints, small to medium parts
shear styles
deformation of the joint, particulate
not suited for polymers with low surface friction (e.g., PTFE)
thin films and fabrics
no special joints are used
tearing, pinholes
polymers must be dielectric for this process
FDA-compliant welding for critical applications
High-volume production and safety-critical components
Food-safe sealing and barrier protection
Precision assembly and environmental protection
Flexible materials and continuous processes
Cost-effective solutions for everyday products
We analyze your parts, materials, production goals, and quality requirements to understand the full scope of your joining challenge.
Risk assessment, process selection, and detailed test plan development with clear success criteria and timeline.
Systematic parameter development using an analytical and experience-based approach to optimize process variables and validate performance.
Final validation testing, documentation package, and knowledge transfer to ensure successful production launch.
Real-world examples of how we've helped manufacturers overcome complex plastic welding challenges.
Problem
Inconsistent ultrasonic hermetic seals (15% rejects).
Approach
Reviewed horn design, geometry, and parameter interactions.
Result
<1% rejects, ~$200k scrap savings; compliance risk reduced.
Problem
Prototype success couldn't translate to high-volume.
Approach
Analyzed tooling variation, improved process control, recommended fixture changes.
Result
99.5% first-pass yield, 20% cycle time reduction, 500k+ units/year launch.
Problem
Invisible, strong welds on transparent lenses to opaque housings.
Approach
Developed parameters for optical performance; recommended joint design for stress distribution.
Result
40% higher strength vs. adhesive bonding.
Let's discuss how we can help you achieve reliable, scalable plastic welding solutions.
Book a Discovery CallStart with a discovery call to discuss your specific requirements and explore how we can help.