Production requirement

How the system addresses it

Portable access

The tool moves to a large or installed assembly instead of moving the part to a press.

Localized joining

Custom tip geometry concentrates energy at selected spots or stakes.

Simple deployment

Compact generator and handpiece suit cells, repair areas and low-volume stations.

Upgradeable method

Fixtures, balancers and guides can improve manual-process consistency.

Application

Typical joining requirement

Automotive trim tack

Localized attachment where the approved manual process is suitable.

Plastic stake forming

Small posts with a custom handheld staking tip.

Large assembly spot weld

Accessible points on parts that cannot enter a standard press.

Prototype and repair

Controlled trial, rework or service operation.

Nonwoven / sheet spot

Selected materials after exact stack and horn tests.

Configuration

Architecture

Best fit

DZ-3512E

35 kHz / 1200 W reference

Fine localized welds and compact tips.

DZ-2808E

28 kHz / 800 W reference

Portable lower-frequency option.

Handpiece support

Balancer or suspension

Reduces operator load in repeated production.

Guided fixture

Locating nest and tool guide

Improves angle, contact and repeatability.

Reference model

Frequency

Rated power

Reference weight

Generator size (W×L×H)

DZ-3512E

35 kHz

1200 W

Approx. 10 kg

450×350×200 mm

DZ-2808E

28 kHz

800 W

Approx. 10 kg

450×350×200 mm

Common reference

28 or 35 kHz

Model dependent

Generator reference

220 VAC; amplitude 10-100%

Environment

—

—

—

Reference operating range: -10 to 40 °C

Parameter

Engineering purpose

Frequency and acoustic tuning

Matches the horn, booster, converter and application; confirmed after acoustic design and trials.

Amplitude

Controls vibration displacement and heat generation; stored by recipe where the generator supports it.

Trigger force or trigger position

Defines when ultrasonic energy starts and reduces variation from part loading.

Weld mode

Time, energy, peak power, collapse/distance or absolute position, depending on controller and validation plan.

Weld force / air pressure

Influences interface contact, melt flow and final joint formation.

Hold time and hold force

Stabilizes the joint before the horn retracts.

Peak power and energy windows

Useful indicators for detecting missing parts, poor contact, tool wear or material variation.

Collapse or final position

Optional measured characteristic for applications requiring dimensional control.

Control element

Available project function

Recipe and access control

Named part programs, controlled editing rights and change history where required.

Cycle result

Pass/fail result based on agreed parameter limits, with clear alarm and recovery logic.

Process data

Time, energy, peak power, amplitude, force/pressure and position values available according to controller scope.

Part identification

Barcode, QR, RFID or manual selection options to prevent recipe/variant mismatch.

Tool and fixture status

Presence, home-position and service-life counters can be included in the control plan.

Line interface

Dry contacts, industrial Ethernet or customer-defined protocol; MES exchange is optional, not standard.

Recipe setting

Amplitude and time settings are established in trials and protected from casual change.

Tool condition

Tip wear, tightness and acoustic response are checked as part of daily maintenance.

Operator method

Position, angle, support and trigger sequence are documented in the work instruction.

Sampling plan

Strength or appearance checks compensate for the higher manual-process variation.

Material or design factor

Application guidance

ABS, PC/ABS, PC, PS

Common ultrasonic candidates when joint geometry and cosmetics are suitable.

PP, PE and other semi-crystalline resins

Feasibility depends strongly on near/far-field distance, stiffness, joint design and fillers.

PA and filled engineering resins

Moisture, reinforcement level and horn wear must be reviewed during trials.

TPE/TPU or soft components

Often challenging; test the exact grade, thickness and support condition.

Dissimilar materials

Do not approve from generic resin names; validate chemical compatibility and melt behavior.

Option

Project scope

Handpiece

Straight or application-specific ergonomic form where available.

Tip / horn

Custom spot, stake, cut or localized joining geometry after acoustic review.

Support

Tool balancer, suspension, holder or positioning guide.

Fixture

Simple nest, back support and datum features for the assembly.

Safety

Trigger protection, cable management and site-specific operator controls.

Acceptance activity

Typical evidence

Documented scope review

Approved specification, layout, utilities, interfaces, cycle definition and exclusions.

Tool and datum verification

Part location, clamp support, tool identity and changeover checks.

Process-window trials

Representative production parts across agreed material and dimensional variation.

Quality checks

Agreed visual, dimensional, strength, leak, burst or functional test with defined limits.

Repeatability run

Quantity, run duration, operator conditions and acceptance method agreed before FAT.

Safety validation

Guarding, interlocks, emergency stops, reset behavior and maintenance access.

Data and alarm test

Recipes, access levels, pass/fail windows, alarms, identifiers and interface signals.

Training and handover

Operation, changeover, maintenance, backup/restore and agreed documentation.

Stage

Main input or activity

Output / decision

1. Application review

Parts, materials, joint, CTQs, takt and plant standards

Feasibility risks and missing inputs

2. Concept and quotation

Process choice, layout, tooling, controls, interfaces and exclusions

Approved technical and commercial scope

3. Trials and samples

Production-equivalent parts and agreed test method

Process window and sample evidence

4. Detailed engineering

3D design, risk review, I/O, safety and documentation plan

Customer design approval

5. Build and debug

Machine, tooling, programs and internal run-off

Ready-for-FAT review

6. FAT

Agreed parts, run quantity, quality checks, takt and documents

Punch list and shipment release

7. Installation and SAT

Utilities, setup, training and site acceptance run

Production handover by agreed scope

Please provide

Why it is needed

Part and joint photos/drawings

Used to check envelope, datums, access, tooling and machine layout.

Exact material and thickness

Required for process feasibility and a grade-level trial plan.

Number and location of spots

Required to complete the technical concept and remove quotation assumptions.

Required strength/appearance

Defines measurable trial, FAT and SAT acceptance criteria.

Cycle frequency and shift pattern

Required to complete the technical concept and remove quotation assumptions.

Need for balancer, guide or fixture

Required to complete the technical concept and remove quotation assumptions.

Question

Answer

Can a handheld welder replace an automatic press?

It can for appropriate localized work, but it provides less control of angle, force and position. Critical high-volume joints generally benefit from a guided press or automated station.

Which frequency should I choose?

35 kHz often suits smaller details and 28 kHz can provide a different balance of amplitude and tool size. Final selection follows part trials.

Can it weld PP or PE?

Possibly, but these semi-crystalline materials can be challenging. Joint design, support, distance and exact grade must be tested.

Is continuous operation possible?

Duty cycle depends on the handpiece, horn, weld duration, cooling and environment. Production rate is confirmed only after a thermal and ergonomic review.

What information is required for an application review?

Please send part 3D data and drawings, exact resin grades, joint or stake details, production-equivalent samples if available, CTQ and test requirements, takt, annual volume, variant mix, utilities and plant standards.

Can Dizo Sonics test our real parts before quotation?

Yes. An application review and representative-part trials are recommended when feasibility, tooling concept or cycle assumptions need evidence. Trial scope, sample quantity and test method are agreed before testing.

How is the final cycle time confirmed?

The committed cycle is based on trials and a complete sequence study including loading, clamping, joining, cooling, inspection, data handling and unloading. Published reference cycles are not universal guarantees.

Which plastic materials can be processed?

Suitability is approved at exact-grade level. Resin chemistry, fillers, moisture, additives, color, recycled content, molded-part variation and joint design can all change the process window.

What documents are supplied with the machine?

The project handover package can include the approved specification and layout, electrical and pneumatic documentation, manuals, maintenance plan, spare-parts list, parameter backup, inspection records and FAT documents according to the contract.

Do you support FAT, installation and SAT?

Yes. FAT and SAT activities are defined in the project plan. Installation, training and on-site support depend on destination, responsibility split and the commercial scope.