Custom End Cap and Felt Ultrasonic Welding Automation Line with Laser Marking

Project Background

A US automotive aftermarket components manufacturer required a customized automation solution 

for assembling and ultrasonic welding plastic end caps with felt components, with the additional 

requirement of engraving traceable text or codes directly onto the end caps using laser marking.

The customer needed a production system that could automatically feed felt components, 

position plastic end caps, perform ultrasonic welding, apply laser marking, and unload finished parts 

with stable and repeatable performance.

TIMEAST developed a custom ultrasonic welding automation line based on the customer's product

structure, production requirements, and factory layout. The system used a vibratory bowl feeding 

solution for felt components, helping the customer improve production consistency while reducing 

manual handling, while also integrating a laser marking system for end cap traceability.

Customer Requirements

The customer required an automation system that could:

• Automatically feed felt components

• Position plastic end caps accurately

• Perform stable ultrasonic welding

• Apply laser marking for traceability on each end cap

• Reduce manual loading and unloading

• Maintain consistent production quality

• Fit within the customer's available production space

Repeatability and process stability were critical due to the application for automotive 

aftermarket components.

Project Challenges

The main challenge was to create a compact, reliable automation line for end cap and

felt assembly with integrated laser marking. Manual or semi-automatic production 

posed several issues:

• Felt components may be difficult to feed consistently

• Manual placement can create positioning variation

• Welding results may become unstable if components are not accurately located

• Laser marking required precise alignment and timing to avoid slowing production

• Operator involvement increased labor dependency

• Production output was difficult to keep consistent over long shifts

The customer required a system that could address these challenges while supporting 

continuous production.

TIMEAST Solution

TIMEAST designed a fully integrated automation line combining:

• Vibratory bowl feeder for felt components

• Automatic transfer and positioning mechanism for end caps and felt

• Dedicated fixtures for accurate assembly

• Ultrasonic welding station

• Integrated laser marking system for engraving text or serial codes on end caps

• Vision inspection system to verify assembly and marking quality

• PLC-controlled operation with HMI interface for monitoring and adjustment

• Automatic unloading structure

• Safety guarding and emergency stop protection

This design allowed the customer to complete the assembly, welding, marking, and 

inspection processes with minimal manual intervention.

Vibratory Bowl Feeding for Felt Components

Felt components were supplied through a vibratory bowl feeding system, providing:

• Continuous and reliable feeding

• Stable orientation for accurate assembly

• Compact layout suitable for the customer’s factory

• Reduced manual handling

• Easy integration with welding and laser marking stations

The feeding system was customized based on the felt component size and shape to ensure

smooth operation.

Automated Production Process

1. Felt Feeding

Felt components are automatically supplied through the vibratory bowl feeder and delivered to

the pick-up position.

2. End Cap Positioning

Plastic end caps are positioned inside dedicated fixtures to ensure accurate alignment before 

welding and marking.

3. Automatic Loading

The automation mechanism places the felt component onto the plastic end cap in the fixture.

4. Ultrasonic Welding

The ultrasonic welding station bonds the felt to the end cap under controlled parameters for 

repeatable quality.

5. Laser Marking

A laser marking system engraves text, serial numbers, or batch codes directly onto the end cap.

6. Vision Inspection & OK/NG Sorting

The vision system verifies assembly, welding, and marking. Defective parts are automatically 

sorted into NG bins while qualified parts are collected in OK bins.

7. Automatic Unloading

Finished and inspected components are discharged to collection bins for packaging or further processing.

Integrated Laser Marking for Part Identification

To support part identification and production traceability, the automation line was equipped with

an integrated laser marking system.After the end cap and felt are assembled and welded, the laser 

marking unit engraves required information directly onto the plastic end cap. The marked information

can be used for product identification, batch management, replacement part recognition, or 

customer-specific coding requirements.

Typical marking content may include:

• Part number

• Batch code

• Production date

• Customer code

• Product identification text

The laser marking process is completed automatically within the production cycle, without requiring 

additional manual handling. This helps the customer improve product identification while maintaining

stable automated production.

Project Benefits

The automation line provided the customer with:

• Stable and continuous felt feeding

• Accurate end cap and felt positioning

• Consistent ultrasonic welding quality

• Traceable laser-marked end caps

• Reduced labor and operator dependency

• Improved production continuity and repeatability

• Compact, integrated solution suitable for limited factory space

Installation and Commissioning

After factory acceptance testing, the automation line was shipped to the customer's facility 

and successfully commissioned for production. The system now supports stable assembly,

 ultrasonic welding, laser marking, and quality inspection of automotive aftermarket components.

Conclusion

This project demonstrates how a custom ultrasonic welding automation line with vibratory bowl feeding

 and laser marking can help a US automotive aftermarket components manufacturer achieve consistent 

assembly quality, traceable marking, and high production efficiency.

By integrating felt feeding, end cap positioning, ultrasonic welding, laser marking, vision inspection,

 and automatic unloading, the system reduced manual handling, improved repeatability, and provided 

a compact solution adaptable to future production requirements.