Plastic Welding

Engineering polymer joining for robust products.

When you’re working with polymers during any stage of product development or production, it’s a challenge to ensure strong, well-sealed welds without compromising component design. EWI can help you develop custom plastic welding solutions.

From plastic welding consulting to process modeling to evaluation, we do more than just find ways to join polymers and dissimilar materials. Our engineers can help you identify which plastic welding process to use (or create a new one), optimize product design for manufacturability, validate the process, guide your team through implementation, and support training and production launch.

Ideally, we start working with our clients at the beginning: part design and process development. Manufacturers that bring us in at a later stage often need to analyze a failure, develop an approach for plastic welding repairs, or redesign tooling or processes.

Our more unique plastic welding R&D capabilities include:

Our Experience with Polymer Welding Technologies

EWI has a 30-year history of engineering plastic welds for innovations in all manufacturing sectors. Our industrial expertise and excellent lab facilities position us to support diverse applications, from micro-welded plastic medical devices and electronics to big-and-strong (yet light) parts for aerospace.

We go all in to meet our clients’ goals, and we’ve been instrumental in breakthroughs over the years, including:

• Developing a method to structurally bond a polymer to metal without adhesives.
• Conducting R&D on the effect of joint design on ultrasonic welding of polybutylene terephthalate (PBT), which proved that a less-expensive, longer-lasting energy director could be used with servo motion control during ultrasonic plastic welding.
• Receiving a patent for ultrasonic technology UltraThinSeal™ for high-speed package film sealing that can be easily integrated into most standard thermal sealing bagmakers.

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