How ultrasonic welding compares to other plastics joining methods

Method

Advantages

Disadvantages

Mechanical fasteners

• Usable on any materials
• Low capital cost - good for prototypes and small batches

• Multiple small components to assemble - extra cost, labour intensive.
• Appearance may be unsightly.
• May loosen in use.
• Potential for consumer to disassemble.

Adhesive bonding

• Adhesives may be available for materials not compatible for welding
• Low capital cost - good for prototypes and small batches

• Longer time to join - parts may need to be clamped or held together until bonded.
• Possible safety issues with emissions.
• Possible problems recycling mixed materials.

Spin welding

• Capacity for larger components than ultrasonic

• Relatively complex equipment.
• Only suitable for axi-symmetric welds.
• Limited to same chemically-compatible material combinations.

Vibration welding

(low frequency)

• Capacity for larger components than ultrasonic

• Relatively complex equipment.
• Limited to same chemically-compatible material combinations.

Hot plate welding

• Capacity for larger components than ultrasonic
• Good for thin, conductive materials eg. laminated metal-plastic foils.

• At least one component must be thin to permit heat transfer.
• Limited to same chemically-compatible material combinations.