April 1, 2002

5 Min Read
Ultrasonic Welder Designed for Delicate Assembly Work

Originally Published MPMN April 2002


Ultrasonic Welder Designed for Delicate Assembly Work

The 30-kHz system integrates a comprehensive process controller and GUI


A 30-kHz ultrasonic welder produces up to 1500 W of power in either a probe or a press-and-thrust system.

Designed for ultrasonic assembly applications that require power and amplitude but are too delicate for 20-kHz systems, a 30-kHz welder provides up to 1500 W of ultrasonic power. Offered in probe and press-and-thrust configurations, the welder supplied by Dukane Corp. (St. Charles, IL) is equipped with a graphical user interface to facilitate tooling manipulation and a choice of process controllers.

Dynamic Process Controllers (DPCs) are available in a choice of four power levels and frequencies. Options range from the DPC 1 (OEM), a compact and customizable design, to the advanced DPC IV with a 32-bit RISC microprocessor. The latter unit provides digital amplitude control in 1% increments, real-time multitasking capability for simultaneous control of process parameters, and primary and secondary control functions to reduce rejects and increase part consistency. It can also be used with the firm's Intelligent Process Control (IPC) software.

The browser-based IPC interface sets parameters and displays part data, providing a complete graphical environment for communicating with the DPC IV ultrasonic system. The software has context-sensitive on-line help and electronic documentation, and it manages a library of up to 99 user-definable setups on the host computer.

Norbert Sparrow

Dukane Ultrasonics, 2900 Dukane Dr., St. Charles, IL 60174; phone: 630/584-2300; fax: 630/584-3162; Internet: www.dukane.com/us; e-mail: [email protected].

Mechanical Testing Goes Mobile

Handheld unit integrates displacement and force measurements


A portable handheld tester comes with a personal data assistant to monitor tests and capture results.

A handheld tester is suited for the measurement of mechanical properties in the field, when it is more convenient to bring the tester to the material or component than it is to bring a sample to the lab. Instron Corp. (Canton, MA) introduced the device, which it claims is an industry first, at the recent MD&M West conference and exposition in Anaheim, CA.

The tester accepts a variety of fixtures and has two modes of operation, says Lorenzo Majno, principal–new ventures at Instron. "The closed-frame mode is used for tension-compression tests, in which the force is reacted against the crosshead," he says. The crosshead can be removed to conduct push-pull open-frame tests. In both modes, the tester applies load or displacement at known, repeatable speeds to ensure consistent results. "Unlike force gauges, this unit integrates displacement and force," Majno stresses.

The Hand-Held Mechanical Tester is equipped with a color personal digital assistant that monitors tests, captures results, and downloads data to a PC or network. Data can also be uploaded to individual testers to provide instructions and work requirements. The tester can be customized with grips, fixtures, and application software to meet specific testing requirements.

Norbert Sparrow

Instron Corp., 100 Royall St., Canton, MA 02021; phone: 800/564-8378; fax: 781/575-5725; Internet: www.instron.com

Adhesive Dispenser Yields High Return on Small Deposits

Dispensing instrument's 0.25-cm3 capacity minimizes material waste


The Mikros is designed for assembly operations that require the use of small amounts of two-part epoxies, UV-cure adhesives, and other costly fluids.

High-performance adhesives with a short pot life can create a sticky situation for medical device OEMs. Because device assembly operations often require very small deposits, two-part epoxies and other premium adhesives with a short shelf life may harden before they can be used up. To reduce material waste in these types of applications, EFD International (East Providence, RI) has developed the Mikros, a dispenser with a small-capacity reservoir that allows manufacturers to mix adhesives in small batches.

The Mikros comprises a lightweight aluminum handle and a disposable reservoir tip. The reservoir can be fitted with a 30-, 32-, or 33-gauge stainless-steel dispensing needle that has a 0.25-cm3 capacity. The device is designed for use with the company's microprocessor-controlled pneumatic dispensers. Together, the pen and dispenser form a system that can produce consistent adhesive deposits as small as 0.007 in. diam.

"We see the medical device sector as one of the core markets for this product," says business development manager Terrence Woldorf. "The Mikros will enable manufacturers who use adhesives with a short shelf life to waste less material and to reduce production costs." If the product is a hit, fluids suppliers at some point in the future may provide prefilled cartridges for use with the device, he adds.

Norbert Sparrow

EFD, 977 Waterman Ave., East Providence, RI 02914; phone: 401/434-1680; fax: 401/431-0237; Internet: www.efe-inc.com; e-mail: [email protected].

Medical Product Manufacturing News is always on the lookout for innovative products and services. If you are aware of any that have recently been or are about to be introduced, please call the Hotline editor, at 310/445-4265.

Copyright ©2002 Medical Product Manufacturing News

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