Dukane Intelligent Assembly Solutions, 2900 Dukane Drive, Saint Charles, IL (2025)

12/17/2025

The 6000 Vibration Welding Technology with Melt-Match® from Dukane.

Smallest Footprint
Provides the industry's largest welding table with the smallest footprint, 25% smaller than current models.

Repeatable process and consistent results
Melt-Match® technology provides a repeatable process and consistent results by precisely controlling all phases of the welding process.

Accurate Control
Melt-Match® parameters control the welding process “in motion” with real-time velocity control. Weld velocity can be programmed into 5 independent segments to match the material's melt flow rate.

Avoid weld joint deformation and cold welds
Melt-Detect™ feature resumes motion once the plastic material has started to melt. By using Melt-Detect™ a user can avoid weld joints deformation and cold welds during the welding process, get uniform melt, and a hermetic seal.

Instant Validation of Good Part
More meaningful data is obtained for instant validation of a good part. It reduces manufacturing costs with improved first-pass yield, and users can easily replicate a proven welding process from one system on additional VW 6000 series systems with 100% electric control and no pneumatics to adjust.

Learn more at Dukane.com

12/15/2025

Dukane’s Infinity™ Servo-driven Ultrasonic Welding technology with patented Melt-Match® helps Muroplás achieve precision, efficiency, productivity, and predictable control.

Muroplás, a manufacturer of a wide range of components for medical and hospital devices, was faced with a major challenge in developing a solution for the new design of the check valve assembly process. The ultrasonic welding technology they were using didn't provide the support and reliability they needed. They were in search of a more efficient solution, so, once again, they reached out to Wondermac Innovative Solutions, Dukane's representative in Portugal. See how Dukane's Infinity™ servo technology allowed Muroplás to achieve high-quality welding, eliminate failures, reduce waste, ensure efficiency, improve productivity, and guarantee more precise and predictable control.

12/12/2025

Dukane: Your Partner in Advanced Laser Welding Solutions

We’re excited to showcase our laser plastic welding solutions designed to meet the most demanding needs of medical devices and component manufacturing in the world! Whether clear-to-color or clear-to-clear plastic welding, Dukane’s advanced technology delivers precision, reliability, and unmatched quality for your plastic joining applications.

Our offerings include:
NRGt: A turnkey, stand-alone, plug-and-play solution designed for easy implementation and exceptional performance.
NRGi: An automation-house-integration-ready system that allows manufacturers to integrate our laser welding technology into their production lines seamlessly.

With our proven expertise in plastic welding, we’re here to help you achieve efficient, repeatable processes and bring your projects to life faster!

Learn more at https://shorturl.at/HgzhB

12/09/2025

Introducing the next-generation Infinity™ Thermal Heat Staking line.

Dukane’s advanced servo-controlled heat staking system, built to meet the evolving demands of plastic staking, swaging, and insertion.

Designed for maximum customization, precision, and control, the Infinity™ Thermal system is equipped with:

+ SmartStack™ cassette-style thermal stack, tool-less, orientation-locking, and easy to swap

+ iQ Explorer 3 an intuitive, high-res touchscreen interface with enhanced navigation and real-time programming

+ New Infinity™ thermal controller — featuring Ethernet-based communication with the servo controller

+ Built-in QA monitoring and real-time closed-loop control for unmatched accuracy

+ STO (Safe Torque Off) for compliance with the most stringent safety standards

+ High-resolution force and distance control — standard 1μm, optional 0.1μm

+ Optimized design for medical-grade expectations and Industry 4.0 connectivity

From precise calibration to plug-and-play stack changes, Infinity™ Thermal redefines what’s possible in heat staking.

Ready to elevate your production line? visit https://www.dukane.com/products/heat-staking-with-infinity-thermal

12/08/2025

Webinar Alert: Choosing the Right Plastic Welding Technologies for Automotive and Beyond

Sponsored by Plastics Technology and Presented by Dukane

Selecting the right plastic welding technology is essential for achieving high performance, durability, and consistent quality for your automotive parts. Learn how various processes, such as ultrasonic, vibration, infrared, hot gas, and laser welding, align with different materials, joint designs, and production goals in automotive and other demanding industries to ensure strong, precise, and repeatable welds that meet today’s manufacturing standards.

+ Plastic welding fundamentals: explore how amplitude, pressure, and material properties interact to achieve optimal welds in automotive applications

+ Design for success: learn to integrate energy directors, shear joints, and spot welds that enhance strength, sealing, and consistency

+ Design for success: learn to integrate energy directors, shear joints, and spot welds that enhance strength, sealing, and consistency

+ Avoiding costly pitfalls: identify common part design and molding errors that compromise joint integrity and performance

+ Advanced techniques and troubleshooting: discover when to apply staking, swaging, and spot welding, plus expert tips for fine-tuning parameters and resolving real-world challenges

Presenter 1: David Cermak
Principal Application Engineer, Dukane

Presenter 2: Ishaan Patel
Applications Engineer, Dukane

Learn more and register: https://shorturl.at/e6FJh

12/05/2025

Thank you, Hygienix 2026!

We enjoyed sharing our patented ultrasonic bonding technologies and discussing the future of absorbent hygiene with ultrasonic bonding with all who visited our booth. We can't wait to see all of you next year!

12/04/2025

Webinar Alert: Choosing the Right Plastic Welding Technologies for Automotive and Beyond

Sponsored by PlasticsTechnology and Presented by Dukane

Selecting the right plastic welding technology is essential for achieving high performance, durability, and consistent quality for your automotive parts. Learn how various processes, such as ultrasonic, vibration, infrared, hot gas, and laser welding, align with different materials, joint designs, and production goals in automotive and other demanding industries to ensure strong, precise, and repeatable welds that meet today’s manufacturing standards.

+ Plastic welding fundamentals: explore how amplitude, pressure, and material properties interact to achieve optimal welds in automotive applications

+ Design for success: learn to integrate energy directors, shear joints, and spot welds that enhance strength, sealing, and consistency

+ Design for success: learn to integrate energy directors, shear joints, and spot welds that enhance strength, sealing, and consistency

+ Avoiding costly pitfalls: identify common part design and molding errors that compromise joint integrity and performance

+ Advanced techniques and troubleshooting: discover when to apply staking, swaging, and spot welding, plus expert tips for fine-tuning parameters and resolving real-world challenges

Presenter 1: David Cermak
Principal Application Engineer, Dukane

Presenter 2: Ishaan Patel
Applications Engineer, Dukane

Learn more and register: https://shorturl.at/e6FJh

12/01/2025

Webinar Alert!

Plastic welding technologies for automotive applications: Choosing the right solution

Discover the keys to improving plastic bonding in automotive parts manufacturing with insights from Dukane's Chief Applications Engineer, Nick Sarver. In this technical webinar, you'll explore how ultrasonic welding is driving next-generation vehicle assemblies through smarter design, material selection, and improved process control.

Discover practical methods for improving the strength, appearance, and reliability of welds on a wide range of thermoplastic components. You'll learn how to avoid common design mistakes, optimize joint geometry, and fine-tune ultrasonic settings to meet today's demanding automotive industry requirements.

What you will learn:

• Basic principles of ultrasound: the relationship between amplitude, pressure, and material limits in automotive applications.

• Intelligent part design: Design features such as energy directors, interference joints, and spot welding to achieve optimal strength and sealing.

• Material behavior in welding: understanding how different resins and additives influence weld quality and long-term performance.

• How to avoid costly mistakes: detect common design and molding errors that lead to weak joints or poor seals.

• Advanced joining methods: when and how to implement riveting, stamping, and spot welding techniques in difficult assemblies.

• Real-world problem-solving: practical tips for adjusting parameters and improving results to meet industry standards.

Wed, Dec 3, 2025 1:00 PM - 2:00 PM CST

Learn more and register:

https://www.linkedin.com/events/tecnolog-asdesoldaduradepl-stic7399484789508198400/

11/27/2025

Wishing you a Happy Thanksgiving and a joyful holiday season filled with prosperity and good cheer, from all of us at Dukane!

11/26/2025

Lightweight materials. Tight tolerances. Complex geometries.

Automotive engineers face new challenges every day, and our plastic welding expert Engineers understand this much better than anyone. So here we are, presenting Dukane’s patented 50 kHz ultrasonic welding technology to deliver:

🔹 Smoother energy transfer for cleaner welds
🔹 Reliable sealing without particulate and parasitic welds
🔹 Reduced flash and rework on critical parts
🔹 Faster cycle times for higher production efficiency

Watch how higher frequency technology keeps automotive production lines moving with speed, repeatability, and precision.

11/25/2025

What is Melt-Match®?

Melt-Match® is Dukane’s patented servo-driven ultrasonic welding technology that precisely controls the entire melt process — from the moment the plastic softens to when it solidifies.

Unlike traditional pneumatic systems that rely on air pressure, Melt-Match® uses servo motion control to synchronize the horn movement with the melting behavior of the plastic. This ensures that both parts reach their ideal melt state at the same time, resulting in:
✅ Stronger, more consistent welds
✅ Improved part geometry and aesthetics
✅ Reliable, repeatable processes with full digital traceability

In short — Melt-Match® takes the guesswork out of plastic welding and turns it into a measurable, high-precision process that delivers quality you can count on.

Dukane Intelligent Assembly Solutions

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