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What is Vibration Welding?

Vibration welding is an economical, straightforward method with short cycle times and few tools necessary, suitable for large-scale production. Vibration welding saves on energy consumption as components don't need to be heated as with hotplate and Infrared welding; and emits almost no fumes during welding making it an excellent eco-friendly choice.

Vibration welding is an extremely straightforward process: two plastic components are held under pressure and vibrated until their edges come into contact, creating frictional heat which melts the polymer where parts meet, before pressure from a machine forces any excess melted plastic away from welding site, creating a hermetically sealed weld that seals air and watertight seals that may also successfully maintain pressure if required.

Application Considerations

Dizo vibration welders are ideal for use in automotive assembly applications such as door panels, intake manifolds, instrument panels, tail lights and lenses, fluid reservoirs and bumpers. Aviation applications of Dizo vibration welders include HVAC ducts, air diverter valves, interior lighting fixtures and overhead storage bins. Appliance manufacturers may employ Dizo welders for dishwasher pumps and spray arms, detergent dispensers or even vacuum cleaner housings. Accessories applications for accessories applications can include business and consumer toner cartridges, point-of-purchase displays, display stands and shelves; vibration welders may assemble chainsaw housings and power tools. Medical applications may include surgical instruments, filters and I-V units as well as bedpans and insulated trays.

Design of Linear Vibration Welding

Linear Vibration Weld Strength: 

The linear vibration welding process yields weld joints with weld strength equal or stronger than any other area on a part, permitting strains and stresses similar to any other part area to affect them equally. As such, linear vibration welding joints often prove resilient against strain and stress alike.

Common Vibration Welded Materials:

Acrylonitrile Butadiene Styrene (ABS-Cycolac)

Acrylic-Styrene-Acrylonitrile (ASA-Geloy)

Cellulose Acetate (CA)

Cellulose Acetate Butyrate (CAB)

Cellulose Acetate Propionate, (CAP)

PolyOxy-Methylene (POM-Acetal & Delrin)

PolyAmide (PA-Nylon & Zytel)

PolyButylene Terephthalate (PBT-Valox & Enduran)

PolyCarbonate (PC-Lexan & Makrolon)

PolyCarbonate / Acrylonitrile- Butadiene- Styrene (PC/ABS-Cycoloy & Bayblend)

PolyCarbonate/ PolyButylene Terphthalate (PC/PBT-Xenoy)

PolyCarbonate/ PolyEthylene Terephthalate (PC/PET-Xylex & Makroblend)

PolyEthylene (PE)

PolyEthylene Terephthalate (PET-Polyester)

PolyMethyl MethAcrylate (PMMA-Acrylic & Lucite)

PolyMethylPentene (PMP-TPX)

PolyPhenylene Oxide (PPO-Noryl)

PolyPhenylene Sulfide (PPS-Ryton)

PolyPropylene (PP)

PolyStyrene (PS)

PolySulfone (PSO-Udel)

PolyVinyl Chloride (PVC-Vinyl)

PolyVinylidene Fluoride (PVDF-Kynar)

Vibration Welding Joint Design:

Each application of vibration welding requires custom joint designs based on factors like the plastic to be joined, part geometry and requirements of the weld. Before finalizing your part design we strongly suggest consulting one of our application engineers first.

Vibration Welding Design Considerations:

An ideal parting line will follow the force applied by the lift table, with sufficient collapse distance accounted for when designing joints; insufficient collapse may result in poor weld strength/quality.

Joint and part clearance must allow for at least.100" linear movement between part halves. Joint contours that deviate more than 10 degrees from their axis of vibration often do not result in sufficient weld strength.

Parts must be rigid; flexibility will lead to poor welding results. Internal walls perpendicular to vibration must also be stiffened so as not to destabilise welding procedures and fail to weld successfully.

Important Factors In Vibration Welding

Five key considerations must be kept in mind when performing vibration welding to achieve long-term, reliable results. No two operations are exactly alike due to varying melting temperatures of polymers, projects' hygiene needs and components' varying shapes; all this should be kept in mind when setting up welding conditions.

Vibrational Frequency: Vibration welding machines typically operate between 100 Hz and 240 Hz. The frequency required to weld your product depends on factors like product size, tooling weight, amplitude requirements and the application itself; larger items like automotive instrument panels and pallets typically use 100Hz machines while common projects like engine manifolds typically utilize higher frequencies that commonly operate at 240Hz frequencies.

Weld Amplitude: As your weld amplitude decreases, so does its vibrational frequency requirement. Higher amplitudes typically result in faster weld times but at the expense of cleanliness - for best results at high amplitudes, lower frequencies should be used for welding.

Pressure: Vibration welding typically operates between 72 to 290 psi and 2,900 psi; although higher pressures are possible. To shorten weld time by increasing the pressure in your system. However, with some plastics it can reduce strength by forcing more molten material away from joining points; larger components require greater amounts of pressure in order to achieve consistent welds throughout their surface area.

Time: Your time of operation will have an effect on the strength of your weld. Vibration welding machines can be programmed either by time or depth settings for optimal welding results.

Penetration Depth: The weld penetration or depth refers to how much material is displaced during welding; this is one of the key determinants of weld strength. A threshold value should be established based on your polymer choice, product you are welding and mechanical requirements of the product being produced; generally speaking 1mm-1.5mm of displacement should achieve sufficient weld strength.

Advantages of Vibration Plastic Welding

No Consumables Are Necessary

Plastic vibration welding requires no consumables beyond the machine itself, eliminating risks and complexity from solvents, glues or fastening agents which may pose additional danger.

Suited For Any Joint Shape

Contrary to popular perception, vibration welding technology has advanced beyond its early days when only suitable for flat plane welds were possible. Now there are tools designed specifically to address complex shapes that vibrating welding can weld together successfully; vibration welding can even join irregular or curved parts together where welding profiles are 10˚ or less.

Vibration Welding Is Compatible With Most Thermoplastic Polymers

Vibration welding is capable of welding virtually every type of thermoplastic polymer, making the technique extremely versatile. Additionally, vibration welding provides an effective means to join two dissimilar yet compatible materials together without leaving visible join lines behind.

No Ventilation Required

No Ventilation Needed Its Traditional plastic welding techniques produce fumes that must be extracted from the production area in an efficient manner. However, vibration welding uses friction instead of an external heat source, and thus produces virtually no fumes, meaning you can safely utilize vibration welding machines on your production line with minimal ventilation infrastructure requirements.

Cost Effective

Vibration welding is an economical option due to several reasons. There are no additional materials or solvents to purchase; energy usage is lower as hotplates don't need to be heated constantly; thirdly, vibration welding has reduced cycle times that ensure greater productivity with lower unit costs per unit and consistent reliability results.

Versatility

Vibration welding machines offer great versatility when processing components ranging from the very small to large. Larger machines such as the Cemas 999 Vibration Welder have an opening of 1,700mm which makes them suitable for large components, while for smaller components the 901 Vibration Welder with 7 standard machine sizes and customizable options is better suited to handling such tasks. For high volume production, multi cavity tooling makes welding multiple parts in one go possible, increasing productivity.

Suitable For Mass Production

Vibration welding tools can easily fit into automated production lines and assembly lines. Their low purchase and operating costs make vibration welding tools ideal for mass production welding applications.

Why choose Dizo?

As technology leaders in plastic welding, Dizo stands out with our customer-centric approach and delivers solutions tailored to suit specific customer applications. Customers with specific requirements are our specialty - we listen, understand and deliver quality products to meet them precisely. Customers looking to start from scratch can rely on us as their consultants, taking advantage of our 15 years of experience to come up with cutting-edge answers for the toughest welding needs. We have successfully served multiple industries with cutting edge technological breakthroughs. Each new project provides us an opportunity to hone our eye for innovation further while keeping customer relationships at the core.

We Specialize in Producing Top-Notch Vibration Welding Machine at Reasonable Price

Our organization specializes in manufacturing, exporting and supplying an assortment of plastic vibration welding machine. Each device in the offered selection is constructed using only high quality raw material according to international quality standards; and these are then rigorously examined on various parameters by our quality inspectors to ensure quality and durability prior to being offered at competitive rates.

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With our unparalleled service features, we are your ideal partner when it comes to custom plastic vibration welding machine solutions. We provide free design support and free tests of customized vibration welding machine. Additionally, our competitive rates with top quality guarantee make us your ideal partner.