Production requirement

How the system addresses it

Large seam capability

Frictional heating acts across the joint rather than point by point.

Controlled endpoint

Time or collapse/depth strategies are selected during validation.

Application tooling

Upper vibrating tool and lower fixture are tuned and supported for the part.

Production evidence

Process curves, functional tests and repeatability runs support acceptance.

Application

Typical joining requirement

Air intake manifold

Long contoured seam with burst, leak and dimensional requirements.

HVAC / air duct

Large plastic shell with accessible perimeter joint.

Automotive reservoir

Compatible materials and seam designed for vibration motion.

Tail lamp / housing

Selected geometries after cosmetic and thermal evaluation.

Industrial enclosure

Large thermoplastic assembly with clamped flat or contoured seam.

Configuration

Architecture

Best fit

High-frequency family

Approx. 210-260 Hz

Lower tool-mass applications; model dependent.

Low-frequency family

Approx. 100-125 Hz

Larger tooling and part envelopes; model dependent.

Time-control mode

Endpoint by programmed weld time

Useful for development and stable applications.

Depth-control mode

Endpoint by collapse/displacement

For controlled melt development and dimensions.

Parameter

Reference value

Engineering note

Reference series

NC-Z150 to NC-Z2000

Seven legacy platform sizes

Frequency range

Approx. 100-260 Hz

Platform and tool-mass dependent

Amplitude range

Approx. 0.1-4.0 mm

Model dependent; confirm peak/peak convention

Reference tool-mass range

Approx. 5-200 kg

Upper-tool limit varies by model

Reference upper platen range

310×330 to 2010×1000 mm

Model dependent

Reference lower platen range

760×450 to 2116×1100 mm

Model dependent

Lift stroke

Approx. 300-800 mm

Model dependent

Process control

Time and depth modes

Six-stage programmable reference

Power supply

380 VAC reference

Destination standard to be confirmed

Parameter

Engineering purpose

Vibration frequency

Selected by machine platform, tooling mass and application size.

Amplitude

Primary driver of heat generation and must be balanced with material and geometry.

Clamp force / pressure

Maintains interface contact and controls melt flow.

Weld time

Time-based endpoint for stable applications or initial process development.

Collapse / weld depth

Displacement-based endpoint for tighter control of melt development.

Brake and alignment phase

Stops relative motion in the correct final position before cooling.

Hold / cooling time

Stabilizes the joint while maintaining fixture support.

Control element

Available project function

Time and collapse/depth

Two complementary endpoints for process control and fault detection.

Frequency and amplitude

Machine status and programmed values monitored during the cycle.

Force / pressure

Verifies clamping conditions and helps detect loading variation.

Final alignment

Brake position and part datum checks protect dimensional requirements.

Tool identification

Optional ID confirms the correct upper/lower tool and loads the matching recipe.

Functional result

Leak, burst, flow, mechanical or dimensional tests according to the customer specification.

Weld curve

Time, depth/displacement and pressure-related results can be reviewed by recipe and cycle.

Tool identification

Machine confirms the installed upper/lower tool before loading the matching recipe.

Alignment check

Brake and final-datum conditions are verified before the part is released.

Functional testing

Leak, burst, flow or strength results are included in the agreed sampling or inline plan.

Material or design factor

Application guidance

PP, PE and TPO

Common candidates for automotive and industrial large-part applications.

PA, including filled grades

Often suitable; moisture and reinforcement require trials.

ABS, PC/ABS and selected PC grades

Feasible with suitable joint design and controlled amplitude.

Glass-filled resins

Can be good candidates but affect tool wear, flash and process settings.

Dissimilar or soft materials

Require grade-level compatibility testing and may favor another process.

Option

Project scope

Platform

High- or low-frequency machine sized from part, platen and tool-mass study.

Tool change

Tool cart, lifting support, quick connectors and identification.

Motion / pressure

Programmable lift and pressure stages by controller scope.

Inspection

Leak, flow, burst, dimensional or vision-test interface.

Acoustic enclosure

Guarding and sound-reduction package based on plant requirements.

Loading concept

Manual, ergonomic shuttle, rotary table, conveyor or robot handling, selected by takt and risk assessment.

Controls

PLC/HMI brand, recipe capacity, user levels, languages and remote-support method confirmed by project.

Poka-yoke

Part presence, orientation, variant, insert, fixture and tool verification.

Traceability

Barcode/QR/RFID, cycle-result storage and customer-defined data fields as an option.

Inspection

Vision, displacement, force, leak, pressure, flow or dimensional checks according to the CTQ plan.

Line communication

Signals or industrial network interface; MES connection only when explicitly included.

Safety

Interlocked guarding, safety doors/light curtains, emergency stops and safe reset concept to destination requirements.

Service package

Training, recommended spares, preventive-maintenance plan, remote support and optional on-site support.

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

Complete upper/lower part 3D

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

Exact resin grades, fillers and moisture condition

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

Joint cross-section and flash-trap design

Required to complete the technical concept and remove quotation assumptions.

Part and anticipated upper-tool mass

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

Strength/leak/burst and dimensional limits

Defines measurable trial, FAT and SAT acceptance criteria.

Takt, variants and utility standards

Used to size stations, automation, changeover and capacity.

Question

Answer

When should we choose vibration welding?

It is a strong candidate for large thermoplastic parts with long accessible seams, sufficient stiffness and a design that permits small relative motion and flash management.

How is the machine model selected?

Part envelope alone is insufficient. Upper-tool mass, required frequency, amplitude, force, stroke, seam and takt all determine the platform.

Can the process be controlled by weld depth?

Yes. Time and collapse/depth modes are available on the reference platform; the final endpoint strategy is validated for the application.

Is the process suitable for Class-A surfaces?

It may be, but fixture contact, vibration transfer, flash and surface protection must be evaluated with production-equivalent parts.

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.