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Is Ultrasonic Welding Feasible Without the Design of Energy Directors (Weld Lines)?

Technically, it is feasible, but it falls within a narrower process window. Since the welding interface lacks an energy-focusing structure, higher input energy or amplitude is required during the welding process. It is recommended to use a Closed-Loop Ultrasonic System such as the T-sonic iS Series or iX Series to ensure stable and repeatable amplitude output.

Additionally, the fixture must provide sufficient and even clamping force to prevent slippage during the welding process. The material needs to have good melt flowability.

Compared to designs with energy directors, the welding strength and process consistency are generally lower in this case. This method is not recommended for applications requiring high structural strength, high gas-tightness, or high reliability.