ESL Housing Ultrasonic Welding with ≤0.07 mm Flatness Deviation

Application
Electronic Shelf Label (ESL) plastic housing welding for consumer electronics.

Customer Pain Points

• Welding surface flatness deviation caused gaps in module assembly and visible cosmetic defects.

• Inconsistent melt depth increased rework and reduced takt time.

  
  

Technical Challenges

• Thin-wall plastic structure, high risk of warpage and over-melting.

• Tight flatness tolerance required for downstream bonding/assembly.

  
  

TEC Solution

• Servo-driven ultrasonic welder with displacement & pressure closed-loop control.

• Custom precision fixture ensuring repeatable positioning and parallelism.

• Optimized horn design for uniform energy distribution.

  
  

Results

• Welding surface deviation controlled within 0.01–0.07 mm.

• First-pass yield improved to ≥98.7%(basic on 10000pcs).

• Stable takt time <2 s/part.

  
  

Submit your sample for a free welding test and process report within 48 hours