A large auto interior manufacturing factory in the Middle East runs several full-auto assembly lines, adopting ABS and PP plastic door panels for vehicle interior assembly processing. In the past, the factory’s production maintenance team used traditional single-point welding tips to splice and repair cracked door panel parts. Nevertheless, this weak welding structure cannot withstand long-term vehicle vibration, frequent door opening and closing as well as alternating temperature environment inside cars. After a short time of finished vehicle use, the welding seams are easy to crack, peel and fall off, which leads to frequent defective products and assembly line shutdowns. Such unreliable welding quality severely disturbs the stable operation of automatic assembly lines and brings heavy rework pressure to the factory daily production.

To thoroughly eliminate the hidden danger of loose and cracked door panel welding joints, the factory gave up old narrow welding heads and formally applied our NO.2 flat ultrasonic welding head for all door panel welding and rework procedures.

This flat welding head is designed with a 12*7mm wide flat working surface and 3mm fixed tooth depth. Uniform ultrasonic vibration energy can form continuous large-area fusion lines on stacked ABS/PP plastic layers in one welding operation. The plastic material fully melts and interlocks between multi-layer panels, forming an integrated high-strength welding structure, rather than shallow surface bonding only. Made of wear-resistant high-hardness aluminum alloy, the welding head maintains stable performance under all-day continuous mass production without overheating or abrasion damage. It matches 28kHz and 35kHz handheld ultrasonic welding guns universally, and the 3mm limited tooth depth avoids piercing thin plastic door panels during welding without pinhole damage. The whole welding process is physical thermal fusion without glue, rivets or chemical additives, complying with automotive interior environmental protection standards.

After six months of mass production application, the factory’s door panel welding failure rate dropped sharply, the rework volume was greatly cut down, and unexpected assembly line pauses caused by broken welding seams were almost eliminated. The service life of finished door panel assemblies was significantly extended, which greatly optimized the factory’s production efficiency and reduced comprehensive manufacturing costs.