Impulse sealing versus ultrasound sealing. Comparison

Plastic sealing is a popular method of joining materials in many industries, such as packaging, medical and electronics. Two of the most commonly used techniques are impulse sealing and ultrasound sealing. The two methods differ in their operating principle, application and technological requirements. The choice of the appropriate technique depends on the type of material, the specifics of the project and the expected results.

Read more: The most important features of impulse sealing

Impulse sealing operation principle

Impulse sealing is based on the use of heat generated by a heating belt, which heats the material at the joining point under a controlled cycle. Once the right temperature is reached, the material surfaces are plasticised and bonded under pressure. Heating is followed by a cooling phase, during which the weld gains durability. This method is particularly effective for the welding of films and technical fabrics, especially for materials with a low melting point, such as PVC or PE. Impulse sealers are available in the offer of the Zemat Technology Group. 

Read more: The most important information about PVC welding

Ultrasound sealing operation principle

Ultrasound sealing uses high-frequency mechanical vibrations to generate heat at the interface between two electrodes. Under the influence of ultrasound, the material particles begin to vibrate, leading to a local increase in temperature and plasticisation of the material. This technique is ideal for precision joining of small parts and plastics with higher melting points.

Read more: Use of sealing machines in the medical sector

Application of both methods

Impulse sealing is mainly used in the production of film and technical fabric components such as blinds, shutters, pergolas, tarpaulins or mosquito nets. It is used wherever durability, aesthetics and tightness of connections are important. This technology is particularly valued in the sun shading and technical fabrics sectors. Ultrasound sealing, on the other hand, works well in more advanced industrial applications, such as the manufacture of small electronic parts, medical or automotive components. Thanks to its very high precision and short working cycles, it enables thin and difficult materials, often of irregular shape, to be joined quickly. Zemat Technology Group offers impulse sealers.

Comparison of advantages and limitations

Both methods have their advantages and applications, depending on the type of material, the scale of production and the expected precision. Impulse sealing is more versatile and economical, especially for large formats, technical fabrics and thicker materials. It makes it possible to achieve tight, aesthetically pleasing and durable joints with relatively simple process control. Although more expensive to implement, ultrasound sealing allows extremely fast work cycles and the joining of delicate or small parts. Its limitation is a smaller range of compatible materials and often the need for more precise component preparation. The choice of the right technology depends on the specific application – Zemat focuses on impulse sealing as a proven and versatile solution for the textile, shading and technical industries.