There are quite a few options for welding plastic parts, including ultrasonics, laser, hot plate and radio frequency. Additionally, parts can be mechanically joined via fasteners, snap fits or adhesives. Each of these processes has certain advantages and disadvantages for production, and each requires vastly different part and joint designs. Therefore, it’s important to determine which joining method is best for the application before finalizing the part design.
There are several factors to consider when deciding on a joining process. Some of the most significant factors are part size, joint strength, cosmetic requirements, material choice and production rate. Once the choice has been narrowed down to a few processes, it is usually helpful to consult a welding or joining expert to review the preliminary part design for anything that might prevent use of a particular process.