Wednesday, June 7, 2017

Happy 38th Birthday "Welder"

Yes! You read it right, we recently celebrated the 38th Birthday of our ultrasonic work station built in 1979 to assemble whistles for SERON® Manufacturing.  This was the first-time ultrasonic welding was used for manufacturing of whistles. Before this, whistles were assembled using adhesives. Mr. Suren V. Seron, current president and owner of Seron Manufacturing designed these whistles and received a patent in 1981. He chose ultrasonic welding to provide a strong and airtight bond of the whistles for maximum sound generation and to eliminate the concern of aging of adhesives. Patented SERON® P-38® whistles are made of high impact shatterproof ABS plastic and are used internationally by professional referees, coaches, dog trainers, teachers and sports enthusiasts. Underground workers in many industries also use P-38® for personal protection as a safety-sounding device.

Birthday Party Celebrations
Established in 1952 Seron Manufacturing is a family owned business in Joliet, IL. It all started when Mr. Suren V. Seron, was a little boy and like any young boy was playing basketball with neighborhood kids. He accidentally dropped his eyeglasses and broke them. He took the glasses to his dad Dr. Seron, who was a dentist. Instead of just fixing the eyeglasses Dr. Seron thought of having something that would secure the glass on the young boys head during sporting activities. Thus, a new product Glass-Gards® was born, which quickly gained popularity among parents of young kids, schools and people engaged in active sports. Soon Seron Manufacturing became a leading manufacturer and worldwide distributor of safety and industrial supplies including safety eyeglasses, Glass-Gards®, badge holders, lanyards, cords and whistles.
Ultrasonic Welding Workcell

Mr. Suren V. Seron joined his family business in 70s and designed SERON® P-38® whistles. Dukane was his preferred supplier to meet the need for a custom-built ultrasonic welding work-cell. Wendell Harley, who is currently the Custom Engineering Group Leader at Dukane was an Engineer at Dukane in 1979 and was involved in the project. A 20 kHz, six-station rotary part indexing ultrasonic welding work cell was built to meet the production goal of SERON® whistles. Today, SERON® P-38® whistles comes in 15 solid colors and 225 dazzling combinations. These whistles can be customized with specific logo, slogan, company or product name molded in the cap. The work cell is still producing quality whistles, which are supplied worldwide to meet custom wholesale and retail orders.
After 38 years of togetherness, Mr. Seron has personalized the work cell and calls it “Welder”. Keith Day, Sales Engineer at Dukane has been assisting Mr. Seron with any service needs for last 10 years and is now a good friend. He invited Mr. Seron to our headquarters in St. Charles, IL to celebrate 38th Birthday of our ‘Welder’. He accepted the invitation and was excited to meet Wendell Harley and other team members. He shared, “Welder is going strong and producing quality whistles to meet demand.”
We celebrated our quality, customer service, and our passion to take on exceptional projects as an opportunity to provide an outstanding solution. We are looking forward to the celebrate Welder’s 40th Birthday with the whole gang in 2019.
For more information on Dukane's custom built work cells visit or call 630-797-4900.

Wednesday, March 29, 2017

Dukane’s ISTeP – New member of Eastman Tritan Medical Toolkit

Dukane's Industrial Standard Test Part (ISTeP), a two-piece cylindrical part designed to test various characteristics of different resins and plastic welding processes, is the new addition to the Eastman TritanTM Medical Toolkit. Each application in the Medical Toolkit demonstrates key attributes TritanTM offers in the medical device and packaging markets.
Eastman TritanTM Medical Toolkit with Dukane’s ISTeP
Complex medical devices often require secondary operations to complete the assembly or fabrication process of molded or otherwise formed parts, which includes bonding, welding and various other joining methods. TritanTM offers a unique combination of toughness and chemical resistance that makes these molded or formed components well suited to secondary operations that complete the assembly or fabrication process. ISTePs made with TritanTM have been successfully assembled using a variety of welding methods including servo driven ultrasonic welding and the recently developed 2-micron laser welding process that allows joining clear unfilled thermoplastic without the need for any absorbing additives.
ISTeP is replacing the I-beam test part that was previously in the Medical Toolkit.  ISTeP’s unique design facilitates a number of testing techniques in which medical device manufacturers can evaluate performance of specific resins, joint designs and welding methods for their particular applications. The ISTeP mold is designed for even filling, preventing warping, sink marks, and ensures consistent wall thickness. The mold design also includes an insert to allow molding of numerous varieties of weld joint designs. Three tabs on the top and three on the bottom portion of the part make it easy to place it into a tensile test fixture. When the welded ISTeP comes apart during the tensile testing, the assembly will do so evenly, avoiding the so-called ‘zipper effect’. An integral port in the lower portion of the part makes it easy to insert an air tube for a static pressure test or burst testing. The ISTeP design also allows for measuring part height before and after welding, determining actual collapse distance. Following video demonstrates ultrasonic welding, pull & leak testing of ISTeP.
The ISTeP injection mold is available upon request from Dukane for firms wanting test parts molded with an alternate material available in Eastman’s family of resins. For more information on Dukane’s ISTeP and other ultrasonic welding products, contact or call 630-797-4900 and for Eastman TritanTM contact or call 423-229-2000.

Wednesday, February 15, 2017

Dukane presenting at The 46th Annual Ultrasonic Industry Association Symposium

UIA 46
The Ultrasonic Industry Association (UIA) is a unique association that brings together manufacturers of ultrasonic equipment, users of ultrasonic equipment, and academicians and researchers involved in ultrasonics. UIA has perfectly managed to blend academic and industrial world interests to boost a wonderful discipline. UIA Symposia are places where one can meet professionals, who practices various non-traditional applications for power ultrasonics. Dukane has been supporting UIA from its early days. Leo Klinstein, VP of Engineering and R&D, has represented Dukane on UIA’s Board since 2005. Annual Symposiums are one of the many ways UIA offers companies access to key influencers in the international ultrasonic community. The 46th Annual UIA Symposium will be held in Dresden, Germany from April 24th-26th of 2017. This event will offer a global focus on the latest advances in ultrasonics in Europe, US and beyond. Leo Klinstein from Dukane, USA and Thomas Daue from Smart Material Corporation /Smart Material GmbH, Germany chair the Symposium. The Monday Medical session chairs are Jay Sheehan, Integra Life Sciences, US and Klaus Van Jenderka, Physik, Sensorik und Ultraschalltechnik, Germany. The Tuesday Workshop chair is Dominick DeAngelis, Kulicke & Soffa Industries, Inc., US. Poster session chair is Margaret Lucas, University of Glasgow. The Wednesday Industrial session chairs are Leo Klinstein, and Rasmus Lou-Moeller, Meggitt, Denmark.

Presenting Dynamic Hold Capability of Servo-Driven Ultrasonic Welding

iQ Servo

Leo Klinstein, will present recent study conducted by him and his team to utilize dynamic hold capability of servo-driven ultrasonic welders during the cooling phase of the ultrasonic welding process. Ultrasonic welding of thermoplastic is widely used by many industries to fuse together two parts in a short time without introducing additional consumables such as fasteners, adhesives, or solvents. Recent development of servo-driven ultrasonic welders, as opposed to pneumatically driven welding machines, introduces unique levels of control throughout the welding cycle. This study focuses on the final phase of the welding process, i.e., the hold cycle, and the benefits that the servo-driven ultrasonic welders can provide to this final phase by controlling both hold distance and the velocity at which this final phase is accomplished.

The ultrasonic welding cycle is divided into four separate phases, contact, heating, melting of the joint detail and cooling or hold phase. Hold phase is critically important for the joint quality.  During this phase, the weld is actually formed and intermolecular bonds and final microstructure responsible for the joint strength are established.

Leo’s presentation would investigate effects of the hold phase settings on weld’s quality with the aim to alleviate the lack of scientifically based recommendations in setting the parameters of both hold distance and velocity during this phase. It would present and compare test results of not only several hold distances but also the velocities used to achieve them. Dukane’s servo ultrasonic welding equipment with patented Melt-Match® technology will be demonstrated at the event. Bob Aldaz, Zdenek Vondra and Veronica Pekarska from Dukane will also attend the symposium.

Symposium Exhibitor and Sponsor Information

There are four sponsorship packages available, each with different levels of access to exposure in the Vibrations newsletter, UIA website and more. Here is the complete information about the UIA Sponsorship Opportunities. Once you have decided your level of participation, complete the registration form for Exhibits and Sponsors.