Design Guidelines

Download our comprehensive guide on Ultrasonic Welding Joint Designs to explore various joint configurations and best practices.

Hollow Stake

• Works well with large diameter studs (no smaller than .080" O.D.)
• Produces a large strong head
• Avoids sink marks on the opposite side of molded component
• Enables parts to be re-assembled with self-tapping screws if necessary
• Aesthetically pleasing (can look "molded" on)

Rosette/Flared High Profile

• Recommended for large diameter posts
• Flares out material for 360 degrees of even holding strength
• Requires accurate positioning
• Not generally recommended for small diameter studs

Knurled Stake

• Alignment is not critical
• Ideal for high volume production
• Available in fine, medium, and coarse knurl
• Reduces cycle time

Rosette Low Profile

• Recommended for large diameter posts
• Flares out material for 360 degrees of even holding strength
• Requires accurate positioning
• Not recommended for small diameter studs

Flush Stake

• Used for applications requiring a flush surface
• Requires sufficient thickness in mating component for countersink or counterbore
• Volume of the boss is crucial to fill the countersink properly

Dome/Conical High Profile

• Generally used with bosses with an O.D. of 250" or less
• Produces a tight stake
• Good for glass filled materials or materials with abrasive fillers
• Typically .750" high (3/4" or more)

Dome/Conical Low Profile

• Generally used with bosses with an O.D. of 250" or less
• Produces a tight stake
• Good for glass filled materials or materials with abrasive fillers
• Typically .375" high (3/8" or less)