Ultrasonic Welding & Converting
Rotary Ultrasonic Plastic & Foil Seam Calculator
Dedicated CAM calculator for packaging engineers, medical pouch converters, and PPE manufacturers. Compute linear acoustic energy density, anvil contact pressures, and vector anvil relief geometries for high-speed continuous ultrasonic bonding.
1. Input Parameters
Rotary wheel line feed rate: 5 - 60 m/min.
Rotary sonotrode acoustic output: 500 - 2500 W.
Seam weld width or knurled wheel band: 1.0 - 15.0 mm.
Anvil-to-horn contact downforce: 150 - 800 N.
2. Calculation Results
Linear Energy Density
0.89 J/mm²
Average Contact Pressure
77.8 MPa
Anvil Rotational RPM (Ø80mm)
71.6 RPM
Acoustic Dwell Exposure
15.0 ms
3. Dynamic Schematic & Tooling Guide
Rotary Ultrasonic Sealing Design Rules:
- Knurled Anvil Pyramid Pitch: To prevent continuous film burning while concentrating stress, vector anvil patterns must use 60°/90° pyramidal teeth with 0.2 - 0.4 mm flat lands.
- Rotary Sonotrode Radial Mode: The rotating horn utilizes Poisson radial expansion to produce radial vibrational amplitudes (15 - 35 μm) perpendicular to the film travel vector.
- Weld Energy Window: Optimum thermal bonding for medical non-wovens (PP/PE) occurs between 0.6 - 1.4 J/mm²; values above 1.8 J/mm² induce polymer degradation and pinhole leakage.