Q: Which applications cannot use ultrasonic welding? How to solve this problem?
A: The main reason why ultrasonic welding can not be used is that the size of parts is too large. There is a limit to the area that can be soldered by a single weld head. If the part requires continuous welding, such as in a sealed container, and the welding area is larger than the maximum size of the weld head, then this is clearly not a feasible application. The most likely solution is to reduce the size of the lid to be welded. Another difficult application is multilayer welding, where you weld multiple parts at different heights on the same part, like a sandwich structure, and then weld them all at once. For such applications, it is always recommended to weld each sub-component separately and then combine the sub-components and perform a final total assembly weld.

Q: If the weld joint is poorly designed or defective, can it be solved by adjusting welding parameters and molds? Or is it better to redesign the parts?
A: To some extent, minor problems caused by defects can be overcome by optimizing the welding parameters or improving the fixture. But in extreme cases, the welding process window for such applications is too narrow to be improved, requiring parts to be redesigned.

Q: When the weld joint design is reasonable, will there be the problem of welding failure?

A: It will fail. In addition to reasonable joint design, high quality molding parts are also very important. We sometimes see designs that look great on paper, but after the parts come out of the injection molding factory, the welding encounters all kinds of problems, such as insufficient strength and not sealing. The quality of injection molded parts is very important. It is important to pay attention to dimensional tolerances, shrinkage marks, warping, parting lines or poor location of the gate. These problems are avoided during the molding process to ensure the maximum probability of welding success.