Perhaps the most critical facet of part design for ultrasonic welding is joint design (the configuration of the two mating surfaces). The joint should be considered when the parts to be welded are still in the design stage and incorporated into the molded parts.

There are a variety of joint designs, each with specific features and advantages. Their selection is determined by such factors as type of plastic, part geometry, weld requirements, machining and molding capabilities, and cosmetic appearances.

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