Automatic Solution for Felt and Plastic End Cap Assembly

This automatic ultrasonic welding line is developed for high-efficiency assembly of 

felt components and plastic end caps. The system combines material feeding, die cutting, 

ultrasonic welding, inspection and automatic unloading into one continuous production process.

It is widely used in automotive filter manufacturing and industrial component production 

where stable quality, repeatability and high output are required.

The complete line can be customized according to your product dimensions, material structure 

and target production capacity.

Operation Demo

Watch the full automated process from raw felt feeding to finished product output

Production Process

• Roll feeding of felt material

• Precision die cutting of felt parts

• Automatic feeding of plastic end caps

• Accurate positioning and assembly

• Ultrasonic welding of felt and plastic

• Automatic weld quality inspection

• Sorting and unloading of finished parts

All stations are connected in one automated production line to reduce 

manual handling and improve efficiency.

Why Choose This Automated Welding Line?

• Increase production efficiency

• Reduce labor dependency

• Lower defect and rework rate

• Maintain consistent product quality

• Support scalable manufacturing

Key Features

• Fully automated line from feeding to final output

• Integrated die cutting and ultrasonic welding

• Strong and clean bonding performance

• Automatic inspection for stable quality control

• Smart sorting and unloading system

• Designed for long-hour industrial operation

Automated Feeding & Transfer Module
Efficient and synchronized material handling from felt feeding to welding stations.

Rotary Indexing Workstation
High-precision mechanical platform for stable and repeatable part indexing.

Applications

This system is ideal for manufacturing:

• Automotive filtration components

• Acoustic insulation felt parts

• Interior felt assemblies

• Plastic + nonwoven bonded components

• Industrial filter end cap products

Materials

• Felt (nonwoven materials)

• Plastic end caps (thermoplastics)

• PP / ABS / PA / PC plastic parts

Technical Capabilities

• Process: Die cutting + vibration feeding + ultrasonic welding + inspection+sorting

• Operation: Fully automatic

• Welding Type: Ultrasonic welding

• Material Handling: Roll feeding system

• Output: High-volume continuous production

Reliable Industrial Control System

Built with Allen-Bradley PLC, HMI interface and SMC pneumatic components for 

stable long-term operation.

●Allen-Bradley PLC  ●Structured Electrical Wiring   ●Clear I/O labeling

Performance Advantages

• 30–50% productivity improvement

• Up to 60% labor cost reduction

• Lower defect rate through  inspection automation

• Less operator intervention

• Stable 24/7 production capability

Standard Machine vs Automated Production Line

Standard Ultrasonic Welding Machine:

• Manual loading and unloading

• Separate production steps

• Lower output efficiency

This Automated System:

• Fully integrated production line

• Minimal labor requirement

• High efficiency and consistency

 Ideal for large-scale automotive manufacturing.

Industrial Safety Design

• Safety light curtain

• Emergency stop system

• Safety door interlock

• Three-color alarm tower

• CE-ready safety design on request

Industrial Safety Design

• Safety light curtain

• Emergency stop system

• Safety door interlock

• Three-color alarm tower

• CE-ready safety design on request

FAQ

1. Can the machine be customized?

 Yes. Each system is engineered according to your product drawings and production targets.

2. What materials can be processed?

Felt, nonwoven materials and thermoplastic components.

3. Is the machine fully automatic?

Yes. Feeding, cutting, welding, inspection and unloading are integrated.

4. Which industries is it suitable for?

Mainly automotive, filtration and industrial component manufacturing.

Sample Testing & Feasibility Evaluation

Before building a custom automation line, we can evaluate your product drawings, 

materials and assembly requirements.

For suitable projects, sample welding validation can be arranged. Tooling or fixture cost

may apply depending on product structure.

This helps reduce development risk and confirms process feasibility before production.

Request a Custom Automation Proposal

Send us your drawings or samples for engineering evaluation, layout proposal and quotation.