Sonic-Welding

Precision Plastic Ultrasonic Welding for High-Performance Thermoplastic Assemblies

At Secondary Solutions Inc. (SSI), we provide precision ultrasonic welding services for thermoplastic components requiring fast, clean, and repeatable assembly. Since 1996, manufacturers have trusted SSI to develop reliable ultrasonic welding processes for products used in medical devices, industrial controls, consumer products, agricultural equipment, and commercial applications.

From engineering prototypes to long-term production programs, our experienced team develops validated welding processes that produce consistent, high-quality assemblies while maintaining tight dimensional and cosmetic requirements.

Whether your product requires a structural weld, cosmetic assembly, or precision joining of sensitive plastic components, SSI delivers dependable ultrasonic welding solutions tailored to your manufacturing needs.

What Is Ultrasonic Welding?

Ultrasonic welding joins thermoplastic components using high-frequency mechanical vibrations combined with controlled pressure.

As the mating surfaces vibrate against one another, friction generates localized heat that melts the plastic at the joint interface. Once the ultrasonic energy stops, the material rapidly solidifies under pressure to create a strong, permanent weld.

The process produces clean, repeatable joints without adhesives, mechanical fasteners, or extended cure times.

Benefits of Ultrasonic Welding

Ultrasonic welding is one of the most widely used plastic joining technologies because it offers outstanding speed, precision, and repeatability.

Benefits include:

• Fast cycle times
• Strong permanent joints
• No adhesives required
• No curing time
• Clean manufacturing process
• Excellent dimensional repeatability
• High production efficiency
• Low operating cost
• Minimal material consumption

For many thermoplastic assemblies, ultrasonic welding provides an excellent combination of performance and manufacturing efficiency.

Our Ultrasonic Welding Capabilities

SSI supports a wide range of ultrasonic welding applications, including:

• Medical device components
• Consumer products
• Industrial controls
• Electronic housings
• Automotive components
• Agricultural equipment
• Sensor assemblies
• Plastic enclosures
• Structural assemblies
• Customer-designed products

Our capabilities include:

• Prototype development
• Process development
• Engineering validation
• Production welding
• Customer-specific requirements
• Fixture development
• Quality inspection

Engineering the Welding Process

Successful ultrasonic welding depends on much more than simply placing a part into a machine.

Every project is developed around:

• Plastic material compatibility
• Joint design
• Energy director design
• Horn selection
• Fixture design
• Weld energy
• Weld amplitude
• Weld pressure
• Weld time
• Hold time
• Collapse distance when applicable

Careful process development helps ensure repeatable weld quality while protecting sensitive components from excessive stress.

Custom Fixtures & Horn Tooling

Every ultrasonic welding application requires accurate part location and properly designed tooling.

SSI develops custom fixtures that:

• Accurately position components
• Support critical features
• Reduce part movement
• Improve repeatability
• Maintain cosmetic quality
• Increase production consistency

When required, we work with tooling suppliers to develop ultrasonic horns designed specifically for each product and application.

Process Development & Validation

Every successful production program begins with a proven process.

SSI supports customers through:

• Prototype welding
• Engineering evaluations
• Process optimization
• First Article Inspection (FAI)
• Validation builds
• Pilot production
• Production readiness reviews

Early process validation helps reduce manufacturing risk while ensuring reliable long-term production.

Selecting the Right Plastic Joining Method

Not every plastic assembly should be joined using the same process.

SSI works closely with customers to evaluate whether ultrasonic welding, spin welding, heat staking, adhesive bonding, or another joining method is best suited for the product's geometry, performance requirements, production volume, and long-term reliability.

Our goal is not simply to weld parts—it's to help customers select the manufacturing process that provides the greatest value and performance.

Quality Inspection

Every welded assembly is inspected to ensure it meets customer specifications.

Inspection may include:

• Visual inspection
• Weld consistency
• Joint integrity
• Cosmetic appearance
• Dimensional verification
• Functional testing
• Customer-specific acceptance criteria

Consistent inspection helps ensure reliable production quality from prototype through full manufacturing.

Integrated Secondary Manufacturing Services

Many customers combine ultrasonic welding with additional manufacturing services performed at SSI, including:

• Spin welding
• Heat staking
• Threaded insert installation
• Adhesive bonding
• UV adhesive application
• Assembly & kitting
• Pad printing
• Hot stamping
• Plastic painting
• Conformal coating
• Potting & encapsulation
• Inspection & packaging

Consolidating multiple manufacturing operations under one roof simplifies project management while reducing lead times and improving quality control.

Industries We Serve

SSI supports manufacturers in:

Why Manufacturers Choose SSI

Ultrasonic welding is only as reliable as the process behind it.

For nearly three decades, SSI has developed ultrasonic welding solutions that combine proven equipment, experienced technicians, custom tooling, and disciplined process development to consistently produce high-quality welded assemblies.

Customers choose SSI because we provide:

• Manufacturing experience since 1996
• Process development expertise
• Custom fixture engineering
• Ultrasonic horn support
• Prototype through production
• Experienced technicians
• Responsive customer service
• Competitive pricing
• Minnesota-based manufacturing
• Consistent manufacturing quality

Whether you're launching a new product or transferring an existing production program, SSI provides dependable ultrasonic welding solutions backed by decades of manufacturing experience.

Production Experience

Since we began tracking, SSI has ultrasonically welded nearly 400,000 plastic-to-plastic parts. Combined with our heat staking and insert installation experience, we have installed over one million brass inserts. These figures are only what we have recorded since we started keeping track; actual production totals are higher.

Frequently Asked Questions

Partner with SSI for Precision Ultrasonic Welding

At Secondary Solutions, ultrasonic welding is more than a manufacturing process—it's an engineered solution for producing reliable thermoplastic assemblies. By combining precision equipment, custom fixturing, process development, and decades of manufacturing experience, we help customers achieve strong, repeatable welds that support long-term product performance.

Whether you're developing a new product or improving an existing assembly, SSI has the expertise to guide your project from concept through production.