Ultrasonic welding of polymer micro fluidic devices by inserting metal parts

Ultrasonic welding of polymer micro structures is an economic and fast joining process but is also limited by the high need for geometrical accuracy required for tight and well-aligned joints. Melting of energy directors by ultrasound is nonhomogeneous especially when large parts are to be welded because the vibration amplitude is not the same everywhere under the sonotrode. This paper shows that the homogeneity of welding is improved by inserting metal parts between the joining partners.