Ultrasonic plastic welding utilizes high frequency, vertical motion to produce heat and the flow of thermoplastic material at the interface of mated parts. Pressure is maintained after the delivery of energy is stopped to allow re-solidification of interwoven plastic at the joint, securing the parts with a homogeneous or mechanical bond. This process offers an environmentally friendly means of assembly as opposed to conventional adhesives or mechanical fasteners.

Looking for the perfect ultrasonic plastic welding solution for your application? Contact Us for more information.


Consumer products, automotive components, medical devices and most all industries use ultrasonic plastic welding. Metal inserts may be secured in plastic and dissimilar materials can often be bonded with proper tooling design. ToolTex specializes in toepad welding applications and has worked on several automotive applications. See below for more information on toepad welding.


Even the simplest, timer based ultrasonic press is capable of reasonable precision, and stepping up to energy based units, linear encoded or servo driven presses greatly enhance highly repeatable assembly with tolerances of less than one one-thousandth (0.001″) of an inch.

Joint Design & Tooling

ToolTex will guide you through the process of determining the best joint type and geometry for the material and application you have developed…before you’ve cut the injection mold. We began as specialists in Plastic Ultrasonic Welding and are long-time partners with the founder of this technology, Sonics & Materials. If your product can be Ultrasonically plastic welded, we can develop the tooling you will need for robust and reliable processing.

Ultrasonic Joint


Most ultrasonic welds are completed in seconds, which eliminates the need for costly consumables… no “screws or glue.” We have customers with Ultrasonic equipment and tooling that have been in service for over a decade with millions of trouble-free cycles. From bench-top welders to fully integrated, multi-thruster arrays, sequencing power from a single supply, ToolTex designs and fabricates the best solution for your processing demands.

Ultrasonic Welding Applications

Toepad Welding

ToolTex has spent years perfecting the toepad welding process using ultrasonics. Through the use of 15kHz ultrasonics, we are able to achieve superior strength when compared to other methods, and the finish is unlike any other.

Because our process forms the design and texture of the toepad during welding, there is no longer a need to have pre-molded parts; only 1 – 1.5mm thick vinyl cutouts are needed.


Ultrasonic Horns



This power supply and converter has 5 years of testing in the market place.

This is small in size, but powerful in application of spot welding, staking and ultrasonic cutting.

It is being used in egg belt welding, manure belt welding, door panel spot welding, ultrasonic cutting and many other applications.

A compact system with a compact price!

Contact us today for more information.

Output Power: 150 watts
Output frequency: 40kHz
Weld Time setting: 0 – 9.99 sec
Amplitude Range: Varies by horn design
Dimensions: 4.25″ x 12″ x 10″ (108 x 305 x 254 mm)
Power Supply Weight: 13.5 lbs (6.12 kg)
Compact Hand Piece Weight: 1 lb (0.45 kg)
Compact Hand Piece Size: 1.5″D x 7”L
Cable Length: 6′


We provide efficient and cost effective assembly methods for any plastic assembly application.

Let us find the best solution for you, call 614.539.3222 for a quote.