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Common Frequency Differences in Ultrasonic Equipment

In ultrasonic plastic welding, frequency (kHz) is a key parameter that influences welding energy, precision, and the suitability for different product sizes. Each frequency range has its optimal application, and there is no absolute "better" frequency; it depends on the product characteristics and welding requirements. 👉 Paired with a Closed-Loop Ultrasonic Welding System, the energy supply efficiency can vary, and energy can be precisely output, improving performance. T-sonic iS Series, iX Series.

1. 15 kHz / 20 kHz (Low Frequency, High Energy)

Characteristics:

  • Large single energy output, high amplitude.

  • Strong penetration, suitable for thick or high-rigidity materials.

  • Fast welding initiation, broad application range.

Suitable Products:

  • Larger or thicker plastic parts.

  • Fiber-reinforced materials (e.g., PA+GF, PBT+GF).

  • Structural parts, automotive components, industrial plastic parts.

Notes:

  • Larger equipment size.

  • Relatively higher noise (especially at 15 kHz).

  • Not suitable for high-precision or vibration-sensitive electronic components.

2. 30 kHz (Medium-High Frequency, Balances Energy and Precision)

Characteristics:

  • Finer vibrations compared to 20 kHz.

  • Significant reduction in noise.

  • High welding stability and flexible parameter adjustment.

Suitable Products:

  • Medium to small plastic parts.

  • Consumer products with high appearance requirements.

  • Plastic housings containing electronic components.

Summary of Advantages:

  • Achieves a good balance between energy and precision.

  • Currently one of the most common and versatile frequency choices.

3. 40 kHz (High Frequency, Precision Welding)

Characteristics:

  • Most delicate vibrations, precise control.

  • Smaller single energy output.

  • Stable welding process, low impact on parts.

Suitable Products:

  • Small, thin-walled or miniature plastic parts.

  • High-precision structural components.

  • Products containing PCB, sensors, or tiny electronic components.

Key Advantages:

  • Less likely to damage delicate components or precise structures.

  • Ideal for medical, electronic, and high-end consumer products.

4. Practical Guidelines for Frequency Selection

  • Larger and thicker products → Choose lower frequency (15 kHz or 20 kHz) for adequate energy penetration.

  • Smaller and more precise products → Choose higher frequency (30 kHz or 40 kHz) for finer vibration and reduced damage.

  • Fiber-reinforced or high-rigidity materials → Prefer low-frequency, high-energy (15 kHz).

  • Electronic products or those with high aesthetic requirements → Prefer high-frequency, low-amplitude (30 kHz or 40 kHz).

5. Importance of Ultrasonic Energy Supply Systems (Key Recommendations)

No matter which frequency is selected, the stability and control of the energy supply system are equally important for consistent welding quality. Key points to consider when selecting an energy supply system:

  • Real-time monitoring of frequency, amplitude, and output energy, ensuring precise energy control.

  • Automatic compensation for load and material differences, improving welding consistency and stability.

  • Preventing excessive or insufficient energy, ensuring high-quality welding results.

  • Improving welding consistency and product yield.

👉 It is recommended to choose a Closed-Loop Ultrasonic Energy Supply System such as the T-sonic iS Series and iX Series for enhanced performance.

Key Takeaway

The choice of ultrasonic welding frequency should be based on the product's size, material characteristics, and precision requirements. Pairing with a Closed-Loop Controlled Energy Supply System ensures stable and repeatable welding quality across different frequencies.

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