Dukane Intelligent Assembly Solutions

Dukane Intelligent Assembly Solutions Dukane is a global leader of Plastic Welding solutions.

04/21/2026

Precision matters, especially when every weld impacts performance, safety, and compliance.

In medical device manufacturing, achieving consistent, hermetic seals on complex geometries is critical.

This video showcases Duakne's patented 360° circumferential laser welding, delivering:
✔️ Clean, particulate-free joining
✔️ Exceptional weld strength and repeatability
✔️ Minimal thermal impact on sensitive components
✔️ Ideal for clear-to-clear and complex assemblies

When traditional methods reach their limits, advanced laser welding provides the control and precision needed to meet the most demanding medical standards.

If you’re working on next-generation devices and facing challenges with part integrity, aesthetics, or validation contact our Medical Experts today https://www.dukane.com/markets-we-serve/medical

Wearable Continuous Glucose MonitorsManufacturing wearable Continuous Glucose Monitors comes with a unique set of challe...
04/20/2026

Wearable Continuous Glucose Monitors

Manufacturing wearable Continuous Glucose Monitors comes with a unique set of challenges. We understand that as a Product or Design Engineer working on these critical devices, you need to:

• Protect sensitive electronics from uncontrolled heat and vibration
• Achieve hermetic sealing against sweat, moisture, and contamination
• Maintain precise and consistent weld quality
• Scale production without introducing variability

This is where many other welding technologies begin to fall short.

Dukane’s Infinity™ Servo Ultrasonic Welder with patented Melt-Match® technology is leading the industry by helping medical device manufacturers:

✔ Control melt flow to protect delicate geometries
✔ Achieve repeatable, validation-ready welds at scale
✔ Minimize flash and particulate near critical pathways
✔ Use low, controlled energy to safeguard internal electronics
✔ Integrate seamlessly into automated, high-throughput assembly lines

So instead of worrying about the weld… You can focus on building devices that patients trust.

💡 Leading where others follow.

New Blog: How to Prevent Flash to Improve ConsistencyFlash is a common issue in ultrasonic welding projects that can qui...
04/17/2026

New Blog: How to Prevent Flash to Improve Consistency

Flash is a common issue in ultrasonic welding projects that can quickly undermine product quality and appearance. Flash, the extra molten plastic or particulate material that escapes from the joint, is often one of the first visible signs that the weld process is not fully controlled. It occurs because ultrasonic welding is a vibrational process, and when the melt extends beyond the intended joint, that material has nowhere to go but out.

While weld consistency depends on several factors, flash is one of the most visible and impactful indicators of variability. When excess melt escapes, it signals that collapse, energy input, tooling support, or part stability may not be properly aligned. Preventing flash is therefore a direct step toward stabilizing weld strength, seal integrity, and overall performance.

Read more: https://shorturl.at/yuNDp

Join Us for A One-Day Seminar On Ultrasonic Welding in San Jose, CAImprove your company’s production by learning from th...
04/15/2026

Join Us for A One-Day Seminar On Ultrasonic Welding in San Jose, CA

Improve your company’s production by learning from the Industry’s Experts and getting hands-on training on the fundamentals of Ultrasonic Welders.

What you will learn

• Ultrasonic welding system setup
• Troubleshooting common welding challenges
• Machine controls and operational best practices
• Application parameter setup
• Process optimization for consistent, repeatable results

May 5, 2026, 9:00 PST
San Jose Hilton | Santa Clara Room
300 S Almaden Ave, San Jose, CA 95110

Presenter: David Cermak

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

Weld smarter with Ultrasonic Staking. Discover expert tips to prevent damage, defects, and downtime.Q. Why does the form...
04/14/2026

Weld smarter with Ultrasonic Staking. Discover expert tips to prevent damage, defects, and downtime.

Q. Why does the formed stud stay in the staking cavity as the horn retracts?

This can happen when the head has not solidified before the horn retracts. To resolve this, increase the hold time. This can also happen when the horn tip is heating, but not allowing the head to solidify. Cool the horn tip or use afterburst.

Q. Why is the base melting before the head forms?

This may be due to multiple factors — the trigger force may be too high, the amplitude may be too high, or the downstroke speed may be too fast. These issues can be resolved by decreasing the trigger force, decreasing the amplitude by changing to a lower gain booster, reducing the amplitude percentage setting, or using amplitude profiling to decrease at the end of the cycle.

Q. Why is the stud collapsing at its base?

This can be caused when the part is not supported directly beneath the stud being staked, trigger force is too high, weld distance is too high, or the weld amplitude is too high at the end of the cycle. To correct this, try supporting the fixture with a metal post under the stud being staked, reducing the trigger force, or using pre-triggering, decreasing the weld parameter, or using amplitude profiling to decrease at the end of the cycle.

Our welding experts are just a click away to solve your welding problems — visit dukane.com/contact-us to get the answers you need.

See all of our nonwoven technology at CIDPEX China 2026 and learn how we're revolutionizing the hygiene industry with ul...
04/14/2026

See all of our nonwoven technology at CIDPEX China 2026 and learn how we're revolutionizing the hygiene industry with ultrasonic bonding. Dukane is leading the way by offering patented ultrasonic bonding solutions tailored for the hygiene industry. At CIDPEX China 2026, we’re excited to showcase our latest technologies engineered for high performance, precision, and reliability.

Whether you're improving product quality, increasing throughput, or tackling sustainability goals, our solutions are built to support your success. Stop by to talk with our hygiene experts and explore how Dukane’s deep ultrasonics expertise can elevate your production line.

Webinar Alert: Advanced Plastic Welding Technologies for Automotive ApplicationsAutomotive applications demand strength,...
04/10/2026

Webinar Alert: Advanced Plastic Welding Technologies for Automotive Applications

Automotive applications demand strength, consistency, and scalability. In this webinar, Dukane experts walk through the advantages, limitations, and ideal use cases for multiple plastic welding technologies. Learn how material choice, part geometry, and performance requirements guide technology selection in automotive manufacturing.

Key Takeaways:

+ Overview of leading plastic welding technologies
+ Matching welding methods to automotive materials and designs
+ Considerations for hermetic sealing and structural strength
+ Automation and high-volume production requirements
+ Design tips to avoid late-stage manufacturing changes

Wednesday, April 15, 2026 1:00 PM - 2:30 PM CDT

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

04/09/2026

Join the Dukane team at INDEX™ 2026 to explore how ultrasonic bonding technology is transforming elastic attachment in hygiene product manufacturing.

Dukane’s Full Panel iQ RAM Ultrasonic Bonding Module enables manufacturers to bond elastics directly to nonwoven materials without adhesives, preserving the elastic's natural stretch and recovery properties.

Using ultrasonic bonding for elastic attachment helps manufacturers:

• Maintain elastic stretch and recovery performance
• Eliminate adhesive usage and reduce consumables
• Achieve clean, precise bond patterns
• Deliver consistent bonding at high production speeds

Designed for continuous, high-speed converting lines, the iQ RAM Module delivers reliable bonding performance while enabling more efficient, sustainable hygiene product manufacturing.

Meet our team at INDEX™ 2026 at Booth 1568 to see Dukane’s ultrasonic bonding technology in action.

Join Us for A One-Day Seminar On Ultrasonic Welding in San Jose, CAImprove your company’s production by learning from th...
04/08/2026

Join Us for A One-Day Seminar On Ultrasonic Welding in San Jose, CA

Improve your company’s production by learning from the Industry’s Experts and getting hands-on training on the fundamentals of Ultrasonic Welders.

What you will learn

• Ultrasonic welding system setup

• Troubleshooting common welding challenges

• Machine controls and operational best practices

• Application parameter setup

• Process optimization for consistent, repeatable results

May 5, 2026, 9:00 PST
San Jose Hilton | Santa Clara Room
300 S Almaden Ave, San Jose, CA 95110

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

04/02/2026

See Dukane at INDEX™ 2026!

Dukane is proud to exhibit at INDEX™ 2026, showcasing the industry’s most advanced patented ultrasonic technologies for the Hygiene and Nonwovens market.

Visit us to see how Dukane’s high-speed, adhesive-free ultrasonic bonding and sealing solutions help manufacturers improve product softness, fit, and performance while reducing energy use, material waste, and maintenance costs. From rotary ultrasonic bonding to precision cutting and sealing, our technologies are engineered for consistent quality, global scalability, and sustainable production.

Meet our technical experts at Booth 568 and discover why leading hygiene manufacturers worldwide trust Dukane as their long-term ultrasonic bonding partner.

Use Code DUKA9958 for your complimentary badge!

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

New Blog: Why Ultrasonic Welds Fail in Medical Devices—and How to Prevent Them Medical tubesUltrasonic welding is widely...
04/01/2026

New Blog: Why Ultrasonic Welds Fail in Medical Devices—and How to Prevent Them Medical tubes

Ultrasonic welding is widely used in medical device manufacturing to join plastic components, delivering fast cycle times, strong bonds, and clean assembly without adhesives or solvents. For many applications, it is the preferred method for producing sealed, high-volume plastic assemblies.

And yet, many engineering teams encounter the same frustrating issue.

A part that should weld simply does not perform as expected.

It may leak during validation testing. It may produce inconsistent strength across batches. Or it may pass in development but fail in production.

In medical devices, these are not minor inconveniences. They can delay regulatory approval, increase scrap during scale-up, or introduce risk into a validated manufacturing process.

So, what’s going wrong?

In most cases, ultrasonic weld failures are not caused by the technology itself. They are caused by the interaction among part design, material behavior, and real-world manufacturing conditions during ultrasonic plastic welding.

Read more: https://shorturl.at/jmVa7

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2900 Dukane Drive
Saint Charles, IL
60174

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+16307974900

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