Ultrasonic welding for sensors - strong connections without heat
Precise welding technology for plastic housings, assemblies and sensors - strong, clean and permanently tight.
Challenges in ultrasonic welding of plastic parts
In connection technology, every detail counts. Anyone who manufactures sensors, housings or assemblies from plastic knows that gluing or soldering is often not an option - too imprecise, too complex, too error-prone.
The goal is a connection that holds permanently without damaging the material or compromising sealing surfaces.
But this is precisely where the challenges lie: The behavior of plastics and complex geometries require experience and an understanding of the process. Even small deviations in energy input, pressure or tool shape can determine the quality of the weld seam. In addition, many customers want a clean, low-particle process that is suitable for sensitive applications - such as in medical technology or fluid technology.
But this is precisely where the challenges lie: The behavior of plastics and complex geometries require experience and an understanding of the process. Even small deviations in energy input, pressure or tool shape can determine the quality of the weld seam. In addition, many customers want a clean, low-particle process that is suitable for sensitive applications - such as in medical technology or fluid technology.
Ultrasonic welding with system understanding
We use ultrasonic welding specifically to join plastic components permanently and cleanly - without glue, screws or additional connecting elements.
The process works with high-frequency vibrations that introduce energy into the material with pinpoint accuracy. This fuses the contact surfaces locally - the material bonds firmly while sensitive electronics remain protected.
Our welding processes are tailored to the requirements of sensor technology. We weld housings, float switches, suction lances and flow monitors directly - including leak testing and process documentation.
The result is compact, leak-proof assemblies with a homogeneous surface that can be perfectly integrated into series processes.
The process works with high-frequency vibrations that introduce energy into the material with pinpoint accuracy. This fuses the contact surfaces locally - the material bonds firmly while sensitive electronics remain protected.
Our welding processes are tailored to the requirements of sensor technology. We weld housings, float switches, suction lances and flow monitors directly - including leak testing and process documentation.
The result is compact, leak-proof assemblies with a homogeneous surface that can be perfectly integrated into series processes.
Advantages of ultrasonic welding at Binsack Reedtechnik
Firm, tight connections
Without foreign material or adhesive
Clean, low-particle processing
Ideal for medical technology and fluid technology
High dimensional accuracy
due to precisely matched tool holders
Short process times
Energy-efficient and reproducible
No thermal load
the electronics or sensitive components
Reliable testing processes
for tightness and strength of every welded joint
Project examples from the field of ultrasonic welding
A practical example: We manufacture housings for flow monitors for a customer in the water treatment industry. The housing halves are welded using an ultrasonic process - completely leak-proof.
Another example: In medical technology, plastic components had to be joined with cast-in electronics - without the use of heat. Thanks to the controlled energy input of ultrasonic welding, we were able to protect the electronics and produce a resilient weld seam at the same time.
Another example: In medical technology, plastic components had to be joined with cast-in electronics - without the use of heat. Thanks to the controlled energy input of ultrasonic welding, we were able to protect the electronics and produce a resilient weld seam at the same time.
Contact - Direct & Competent.
Why ultrasonic welding works so well in our production
Ultrasonic welding is not a standard process - it requires experience, intuition and the right design of material and tool.
We develop each welding tool ourselves, tailored to the respective component. The frequency, pressure and welding time are precisely matched to the geometry.
Our welding systems are integrated into our production line and equipped with process monitoring. Every welding process is documented - from energy absorption to seam quality.
The result is not only a strong connection, but also a reproducible process that delivers consistent results even with large quantities.
This combination of experience, toolmaking and process control makes our ultrasonic welding a central component in our sensor production.
Our welding systems are integrated into our production line and equipped with process monitoring. Every welding process is documented - from energy absorption to seam quality.
The result is not only a strong connection, but also a reproducible process that delivers consistent results even with large quantities.
This combination of experience, toolmaking and process control makes our ultrasonic welding a central component in our sensor production.
Ultrasonic welding at Binsack Reedtechnik
We are a medium-sized company based in Mühlheim am Main - specializing in sensor solutions, assemblies and their production. For over 30 years, we have combined an understanding of technology with a high level of vertical integration.
Ultrasonic welding is an important part of our production chain: from toolmaking to plastics processing and assembly, everything is done in-house. This independence ensures short distances, quick adjustments and stable quality - exactly what our customers from industry, mechanical engineering, medical technology and water technology appreciate.
Our customers benefit from direct communication with our technical team, practical advice and implementation that works without detours.
Ultrasonic welding is an important part of our production chain: from toolmaking to plastics processing and assembly, everything is done in-house. This independence ensures short distances, quick adjustments and stable quality - exactly what our customers from industry, mechanical engineering, medical technology and water technology appreciate.
Our customers benefit from direct communication with our technical team, practical advice and implementation that works without detours.
Ultrasonic welding with experience and system
Our ultrasonic welding joins plastics cleanly, permanently and economically.
Thanks to the combination of in-house production, toolmaking and quality testing, we deliver welded joints that deliver what they promise - with high repeatability, clear process control and short delivery times.
When you work with us, you get more than just a connection -
you get a system that works.
When you work with us, you get more than just a connection -
you get a system that works.
Ultrasonic welding directly from the manufacturer
Are you looking for a manufacturing partner who can reliably weld your plastic parts or assemblies?
Then talk to our team directly - we will check your requirements, advise you on material selection and implement your joining solution quickly and economically.
Start your project now - send an inquiry and receive feedback within a few working days.
Start your project now - send an inquiry and receive feedback within a few working days.
FAQ - Ultrasonic welding at Binsack Reedtechnik
Which materials can be welded?
We process thermoplastics such as PA, PP, PE and POM.
Is ultrasonic welding suitable for housings with electronics?
Yes, because the process does not require extensive heating, sensitive electronics remain undamaged - ideal for sensors or measuring units.
How tight are the welded joints?
Our welded joints achieve tightness levels up to IP68. Each assembly can also be tested with pressure or underwater tests.
Can small quantities be produced?
Yes, we manufacture from small series - particularly advantageous when prototypes or pre-series are to be tested.
How is the quality of the weld seam checked?
Welding processes are individually adjusted and optimized for each product. The welded part, such as the float, is 100% tested after welding by means of a water test.
Is ultrasonic welding also possible for complex geometries?
Yes, thanks to individually manufactured welding tools and customizable parameters, we can also cleanly join complex shapes or multi-part assemblies.