As the medical device industry continues to advance, dilators, as an important type of medical tool, have their quality and performance directly related to the treatment effect and safety of patients. From urethral dilators used for medical examinations to skin dilators in the field of plastic surgery, strict requirements are placed on the sealing, structural strength and sterility of the products. With its high precision, high efficiency and intelligent characteristics, Nanning servo ultrasonic welding machines are becoming key equipment in the dilator manufacturing field, helping companies achieve a dual improvement in product quality and production efficiency. This article will deeply analyze how this technology can bring innovation to dilator manufacturing from three dimensions: specific application scenarios, technical advantages and equipment recommendations.
Nanning ultrasonic welding machine welding application scenarios in expander manufacturing
Tight welding of the expander body and connecting parts
The connection between the dilator body and the connecting parts (such as handles, catheter interfaces, etc.) must have a high degree of firmness and sealing. Taking the urethral dilator as an example, traditional welding or bonding processes are prone to problems such as loose connections and leakage, which affect the normal use of the device. The Nanning servo ultrasonic welding machine generates heat through high-frequency vibration friction, which can achieve seamless welding of the dilator body and connecting parts made of medical-grade plastics (such as PP, PE, etc.). The weld is firm and smooth, and the sealing is improved by more than 70% compared to traditional processes. For example, the welding of a common urethral dilator body and handle can be completed within 0.002 seconds, ensuring that the operation will not be affected by loose connections during use, while ensuring the sterility of the product.
Precise welding of film and frame
In products such as skin expanders, a soft film needs to be welded to a hard frame. The servo ultrasonic welder supports micron-level welding accuracy. Through intelligent parameter matching (such as time, pressure, and amplitude), it can accurately locate the welding point and firmly weld the film to the frame, avoiding film damage or frame deformation due to overheating or improper pressure during the welding process, while maintaining the flexibility of the film and the structural strength of the frame. In the manufacture of skin expanders, this precise welding ensures that the product will not leak or rupture during the expansion process, ensuring the treatment effect.
Integrated fusion of multi-layer composite materials
Some high-end expanders use multi-layer composite materials, such as antibacterial materials for the inner layer and high-strength plastics for the outer layer, to meet different functional requirements. Servo ultrasonic welding technology effectively breaks through the compatibility problem of dissimilar materials through molecular layer fusion, ensures that the strength of the connection is close to that of the raw materials, avoids thermal stress damage caused by traditional welding methods, and ensures the overall performance of the product. For example, in some expanders used in special medical scenarios, ultrasonic welding achieves a perfect combination of multiple layers of different materials, improving the overall performance of the product.
Technical advantages of APSONIC servo ultrasonic welding machine
Intelligent servo control, breakthrough in precision and efficiency
The APSONIC servo ultrasonic welding machine is equipped with a fully closed-loop servo control system. The welding pressure, stroke, and speed can all be digitally controlled with an accuracy of 0.005mm. When welding thin-walled expander films, the system can automatically adjust the amplitude and pressure to avoid overheating and deformation of the material, and the yield rate is increased by more than 50%, greatly improving production efficiency and product quality.
Multi-mode adaptability to complex process requirements
It supports 8 welding modes including time, energy, and stroke, and has multi-stage pressure and speed control functions. In response to the welding requirements of different materials (such as medical-grade plastics, special alloys, etc.) in expander manufacturing, the parameter formula can be quickly switched to achieve "one machine for multiple uses", reduce equipment investment costs, and meet diverse production needs.
Green production and data management
The welding process does not require glue or chemical solvents, has zero VOC emissions, and meets the strict environmental and health standards of the medical device industry. At the same time, the equipment has a built-in MES system interface that can monitor welding data in real time and generate quality reports, making the entire production process traceable, facilitating quality control for enterprises, and ensuring that the quality of each expander product meets high standards.
APSONIC servo ultrasonic welding machine: the best solution for expander manufacturing
Among many brands, APSONIC Ultrasonic, with 30 years of technological accumulation, is the first company in China to master the technology of servo-controlled pressure ultrasonic welding machines. Its L3000 Servo and K3000 Servo ES series equipment are particularly outstanding in expander manufacturing:
High precision and flexibility
The L3000 Servo supports 0.001 second time control accuracy and 0.005mm stroke accuracy, which is suitable for precision welding of micro or complex expanders and can meet the high-precision medical product manufacturing requirements. The K3000 Servo ES can store 99 sets of parameter recipes to meet the production needs of multiple batches and multiple materials of expanders. Whether it is large-scale production or personalized customization, it can efficiently complete the task.
Intelligent Operation and Maintenance
The equipment supports WiFi/4G remote diagnosis and program upgrades to reduce downtime. Through cloud data management, engineers can optimize parameters in real time to ensure the welding stability of different batches of raw materials, solve problems that arise during the production process in a timely manner, and ensure production continuity and product quality stability.
Customized service
For the special structure or special material of the expander (such as degradable medical materials), APSONIC provides full-process support such as mold design and process debugging. Starting from the product design stage, APSONIC's professional team works closely with the company to customize solutions according to specific needs, helping the company to quickly achieve technological upgrades and launch higher-quality and more innovative expander products.
Nanning servo ultrasonic welding machine is reshaping the process standard of expander manufacturing with "precision, intelligence and environmental protection" as the core. As an industry leader, APSONIC provides efficient and reliable solutions for expander manufacturers with its technical strength and service system. In the future, with the continuous development of medical technology, the performance requirements of expanders will continue to increase. This technology will promote the implementation of more innovative designs and help Chinese manufacturing take a leading position in the global high-end medical device market.
