Telsonic Cut’n’Seal Technology – A Smooth Operator

As consumers we give little if any thought to the processes used to manufacture the products which we take for granted and use every day. Cut’n’Seal is a process which uses ultrasonic energy to cut or punch out a range of thermoplastic and synthetic type materials, whilst at the same time sealing the edges and if required, joining the individual component to a secondary item. The process can be applied to a range of substrates including very thin density synthetic melt blown or spun bond flexible materials, thicker soft materials and even injection moulded substrates. The vibrations produced by the ultrasonic system cause a cutting effect through the single or multi-layer substrates against a support anvil which incorporates the required cutting contour. The instantaneous heat produced in the cutting zone results in a weld along the cutting edge and the characteristic smooth edge finish. Multi layer substrates or laminates are also collated and fused into one smooth edge. Continuous Cut’n’Seal processing is also prominent in many converter type industries producing bulk synthetics for consumer products. The process has proven to be unrivalled in the quality of finish achieved and therefore adds value to the product being produced.

This smooth edge however is far more than just an aesthetic finish. On items such as medical compresses, which are made up from perhaps 5 individual layers, the sealed edge ensures that there will be no “frayed” edges or loose threads and that the individual layers do not de-laminate. These features are especially important on the vast range of items produced for the medical industry and also important for components such as filters and respiratory masks. Another major user of this technology is the textile industry. The Cut’n’Seal concept enables items such as garment labels to be produced with ultra-smooth edges, an essential attribute for an item which will be in constant contact with the skin.

It is not only small or delicate components which benefit from this process. Ultrasonics has also been used to punch the holes required for parking sensors in polypropylene automotive bumpers, combining the high energy output available from Telsonic’s systems with powerful pneumatic actuators and 2 stage hole cut & form anvils. Although heat is generated during the process, it is local and highly focused so there is no discolouration of the material and the ‘forming’ finish to the cut relieves the risk of paint stress cracking on the painted “A” surface. This allows the process to be used on painted bumpers, without risk of damaging the high gloss finish surrounding the parking sensor hole. The ability to perform this process on finished bumpers provides a much greater degree of flexibility for the manufacturer and enables them to produce a “standard” bumper which can then be customised as required for vehicles to be fitted with this option.

The principals of Cut’n’Seal can be extended to enable the process to perform a welding operation immediately following the cutting process. Termed Cut’n’Weld, one example of this principal is the production of specialist medical consumable filters. Operating in a fully automated configuration, the filter media is fed from a reel into a machine which also presents and aligns the plastic moulded filter frames. Telsonic’s ultrasonic technology is then used to initially cut the filter membrane from the reel of material, before welding it to the plastic moulding. This concept eliminates the need for pre-cutting and collating filter membranes for subsequent presentation to a separate assembly and welding machine. The Cut’n’Weld concept can also be used in a semi-automatic configuration if required, for lower volume products.

With a track record spanning over 40 years, Telsonic has pioneered the use of ultrasonic technology within many applications and industries. The extensive applications knowledge acquired during this time enables Telsonic’s engineers to work closely with their customers to evaluate, not only the best hardware configuration for the application in hand, but also provide valuable advice and recommendations on material match, joint design and concepts which are essential elements of any successful Cut’n’Seal or Cut’n’Weld project.