Efficient Ultrasonic Automated Welding Of Automotive Spoilers

Ultrasonic plastic welding, efficient and eco-friendly, is key in automotive manufacturing. With rising new energy vehicle adoption and automation, it will expand into lightweight components and sensor packaging, driving greener and smarter automotive production.

Working Principle

The working principle of ultrasonic plastic welding is to utilize high-frequency ultrasonic vibration energy. The mechanical vibration is transmitted to the joint surface of the plastic parts through the welding head. Under the action of pressure, the vibration energy is converted into thermal energy, which causes local melting and fusion of the plastic molecules, thereby achieving a fast, strong, and clean connection.

Application

Ultrasonic plastic welding technology, with its high efficiency, environmental friendliness, and precision, is widely used in the production of automotive interior and exterior components, mainly in the following areas:

(1) Interior Components  

Instrument Systems: Precision welding of instrument panels, dashboards, and center consoles to ensure airtightness and surface smoothness, avoiding creaks caused by traditional screw fastening.  

Door and Storage Components: Welding of inner door panels, glove boxes, and storage box covers, supporting seamless connections of multi-materials (e.g., ABS + fabric) to enhance aesthetics.  

Sound Insulation Systems: Spot welding of door sound insulation felt and roof lining to improve vehicle NVH performance.

(2) Exterior Components  

Lighting Systems: Sealing welding of front headlights, taillights, and turn signal housings to achieve IP69K waterproof ratings.  

Body Panels: Welding of bumpers, fenders, and spoilers, supporting lightweight design with carbon fiber composite materials.  

Functional Components: Welding of fuel filler caps, air filter covers, and engine hoods, balancing strength and durability.

Prospects

With the increasing penetration of new energy vehicles and the growing demand for lightweight and high-performance materials, ultrasonic plastic welding machines are poised for broad market expansion
Material Innovation: The urgent need for lightweighting in new energy vehicles has led to the widespread use of composite materials such as carbon fiber and glass fiber-reinforced plastics (GF-PA6). Ultrasonic welding has become a key technology for integrating these multi-materials. Demand for Electrified Components: There is a surge in the demand for sealing welding of components like battery casings and charging port covers, which require high airtightness and vibration resistance.

Specification Parameters

Advantages

No Adhesives/Screws: Reduces stress concentration and enhances component lifespan.

Ultra-fast Welding: Capable of welding in just 0.2 seconds, suitable for high-speed automated production lines, with efficiency more than doubling compared to traditional processes.

Cost-effective and Versatile: Offers cost savings while being adaptable to multiple materials.

After-sales Service Provided:

1.One-year warranty service

2.Online support, Video technical support