Dukane FAQ | Laser Welding, Ultrasonic & More

Ultrasonic and laser welding enable medical device assemblies to meet critical requirements such as hermetic sealing, biocompatibility, and sterilization resistance—without the use of adhesives. Both methods are cleanroom-compatible and support regulatory compliance through consistent, traceable processes. Ultrasonic welding offers high mechanical strength and extremely fast cycle times, making it ideal for high-throughput production. Laser welding provides exceptional precision and cosmetic quality, especially for transparent or microfluidic components. Together, these processes deliver strong, reliable, and sterile joints suitable for demanding medical applications.

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Tool ID in a Dukane machine is simple binary input to the machine through the tooling connector. By wiring 24 volts to the correct pins it is possible to give a tool a unique tool ID. In using this each time you plug in the tool the program associated with the tool will be pulled up in the PLC/HMI. So there is no chance to get the wrong weld parameters for a given application and no reason to set up parameters when you load the tooling.

This is the way you Zero the weight of the tool and the table. Allow you to know that the force you are developing is what you are putting on the part during weld. In some machines you enter the tool weight directly and the machine knows the weight of the table and subtracts both from the pressure in the system. The more accurate way to do this is called “Float the Table”. In this case you load the tooling and run a process of increasing pressure until the table moves. That is where the force to lift is zero. Then this pressure is subtracted from the force of the system.

An un-balanced tool will not run linearly. It will start to move in a orbit form. This stresses the lamination carriers and the Coils. A balanced tool is the single most important thing you can do to make the machine last longer.

The bolts in all spring and lamination carriers must be used. The upper moving tool develops up to 208g’s. This means a 100 pound tool will dynamically produce 20,000 pounds + of dynamic load. Electrically we can see one bolt missing and the head to begin to run not in a desired mode. Multiple bolts missing will damage the machine and void a warranty.

Hold pressure should not exceed weld pressure. In fact it is nice to reduce hold pressure by 10% or so. When a welder goes into hold mode you get “post weld collapse” and this is a thinning of the heat affected zone. This thinning is a reduction in weld strength. You need hold pressure but excessive pressure can yield a cold weld.

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In general the marks are from the part moving in the nest (could be upper or lower nest or both). You need to increase weld pressure so the parts lock up in the nest better. This usually solves the problem. If not finding a way to lock the part on the tool may be required. The use of locators and return flanges in your part usually will work fine.

We need to be thinking pressure and amplitude. If you have a weld in an area where you do not want a weld you need to remove the pressure or remove the amplitude. Usually this means you need to clear the supporting nest in this area relieving any chance that pressure is applied to the area of unwanted weld. Only in rare occasions is it possible to reduce or eliminate the amplitude.

If possible, it is usually better to weld in melt down distance. This is the only closed loop welding method. You can change pressure, amplitude, and even surface area of weld part to part and still make the same distance giving you consistent welds.

A melt map is usually done at 0.5mm or half the desired weld depth. By welding the part at minimum weld depth tearing the part and looking at all weld beads you will find areas of no weld. You would add shims to the tooling until you get around 80% of all areas welded. Then weld the part at full melt depth and check to see if you are making all critical characteristics of the part that are required.

Auto tune is the matching of the natural resonance of the head to the digital drive. When this matching of the frequency occurs, you get lowest possible power draw from the power supply. A small deviation of even 1Hz can mean a lot of lost power. This excess power will show up in your coils of the vibration head causing excessive heat which over time can damage the coils and or lamination carriers. An auto tune can and should be done at every change in tooling. It also can be done in between tooling changes. Dukane machines can be autotuned on a set number of cycles.

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