Sonic Welding


Sonic Welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld. For 50+ years, we have utilized this capability and continue to discover innovative methods and projects.  
Markets served are medical, pharmadeutical, healthcare, safety, electronic, retail, industrial, automotive, manufacturing, construction, agriculture, sporting, cosmetic, and more. Contact us for more information on how we could work with you on your next Sonic Welding project.
Polypropylene, PolyetheleneSpecifications and Equipment:Equipment: Sonic Welding250,000 Sq. Ft. Facility

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RF Heat Sealing and Thermoforming

onX Hunt Blister Packaging

OBJECTIVE: Manufacturer needed a package to promote the purchase of their hunting programs.  
SOLUTION: A custom digitally printed blister card was designed to house the program access code and a game license holder. The game license holder was heat sealed vinyl and digitally printed. Both items were sealed together to create a complete package for the retailer to present for sale.
PROCESSES: Design, Prototype, RF Heat Sealing, Decoration (Digital Printing), Thermoforming, Blister Packaging, Carton and Ship.
SUBSTRATES: Suedene Vinyl, Blister Packaging, PVC

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Thermoforming and Injection Molding

BEI Insulator/Shield Covers

OBJECTIVE: The facility needed a cost effective method to reduce the levels of dust in the work environment. Electrified pipes with injection molded white isolators were hung from the ceiling which emit electrons that cause the dust to settle. This resolved the issue of the dust in the work environment, but caused a secondary problem. The dust also settled on the white injection molded isolators themselves which caused a fault shutting the system off. 
SOLUTION: A dust shield was designed. This PVC Cover for BEI Insulator/shield was thermoformed and die cut. The shield was a clear case that locked around each isolator to protect it from the dust. The company’s logo was also thermoformed into the dust shield. The dust removal gave the workers’ healthier surroundings. In addition, down time and frustration of system faults caused by the dust were dramatically reduced.  
PROCESSES: Design, Prototype, Thermoforming, Injection Molding, Die-Cut, Carton and Ship.
SUBSTRATES: Clear PVC, Polyproplyene