The challenge was attaching multiple leaf springs to an insert molded plastic part with electrical conductors. Riveting these leaf springs in place was not an option. Therefore, the company wondered if ultrasonic welding could meet volume manufacturing requirements and quality standards.
According to Rick Winfree, president, "Insert molding accounts for about 70 percent of our work. It is a highly specialized and rapidly growing business. Auto manufacturers are looking for ways to reduce part counts, cut assembly costs and improve quality. Insert molded parts are a little like irregularly-shaped, three-dimensional circuit boards. But unlike board manufacturers who literally print a low-voltage circuit on a flat surface, we insert copper carriers into precision plastic components, leaving the terminals exposed."