Hybrid Vibration Welding

Vibration welding with an IR preheat for cleaner parts

Hybrid vibration welding uses an infrared preheat to soften the weld ribs before applying linear vibration to join the parts together. This innovative process improves weld aesthetics and reduces particulate flash.

How does hybrid vibration welding work?

Two components are vibrated in shear against each other generating heat from friction. Vibration stops and pressure is maintained while the components bond to one another.

Hybrid vibration welding adds an infrared (IR) preheat to the beginning of the cycle to soften the rib and reduce the amount of particulate flash generated from the vibration cycle.

Preheat

Two components are brought near an infrared heating element to preheat the weld joint.

Clamp

The infrared heating element is retracted, and the components are clamped together.

Vibrate

The upper component is vibrated against the lower component, generating friction and heat.

Cool

Vibration stops and clamp pressure is maintained until the weld cools.

An impressive machine

Extol has partnered with CEMAS to bring you the best hybrid vibration welders. These impressive machines are highly customizable to meet any customer’s needs.

Hybrid Vibration Welder Benefits

Highly customizable

Even with many included standard features, we offer a full range of over 60 options to meet your specific needs.

Clean weld joint

Hybrid vibration welding softens the joint with IR preheat before the vibration process to minimize particulate flash.

No compromise for quality

All components are from world leading suppliers. Safety is our ultimate goal, as well as a prompt availability of spares worldwide.

Easy maintenance

The latest-generation electronic components and strategic placement of the hydraulic unit have resulted in a remarkably smaller control panel. It has also made tooling maintenance and setup operations easier.

Innovative and user-friendly UI

The graphical interface is the most intuitive on the market. Language selection, parameter adjustment, and user-configured I/O is as easy as the touch of a button.

Ergonomic loading

To minimize strain on the backbone, the loading/unloading area is as close to the operator as possible. Our vibration welders have a shorter loading distance than any other machines in their class.

Hybrid welding and 4 reasons why you might need it

  • To optimize weld aesthetics and reduce particulate flash
  • To avoid stringing
  • To reduce stress in the weld joint and improve strength
  • To weld geometries that may not be feasible using vibration welding alone

Vibration Welder Models

There are several different vibration welder models available.

901

Small and Efficient

Ideal for welding small to medium size taillights, intake manifolds, and glove boxes.

902

For Frequent Tool Change

For particularly tall components and very quick and frequent tool changes.

911

Compact and Flexible

Ideal for welding large rear lamps, intake manifolds, spoilers, etc.

912

Born Hybrid

The most advanced in the range, it combines vibration and infrared technology within a compact body.

918

Big Inside

Born to weld the same products welded by 911, but require a stronger welding force and an increased workspace.

950

Cost-Effective and Solid

Highly sturdy for welding large components. Ideal for small to medium sized instrument panels.

999

Powerful and Reliable

This is the largest machine and can be used for large instrument panels, pallets, and outdoor furniture.

Features

Real-time tuning

Real-time tuning adjusts the vibration frequency every 5 ms to ensure a perfect match between the resonating tool mass and the characteristics of the application.

Wide rear opening

Wide rear opening in the back of the machine for easier tool changes.

Quick vibration stop

Vibration can be stopped in less than 50 ms for a more homogeneous and strong joint.

Learn how to design for hybrid vibration welding.

A properly designed weld joint is important to achieving a strong weld. Follow our easy-to-use guidelines to optimize your part design for hybrid vibration welding.

Learn more about hybrid vibration welding on our blog.

The energy in vibration welding

The energy in vibration welding

Recently, we’ve been discussing conventional vibration welding and hybrid or ‘clean’ vibration welding. Vibration welding, a linear frictional weld method, you probably know all about. Hybrid – the introduction of an infrared preheat function prior to the conventional vibration weld process, is a relatively new method of welding plastic parts.

read more
What is the difference between vibration and ultrasonic welding?

What is the difference between vibration and ultrasonic welding?

Occasionally people will confuse vibration welding and ultrasonic welding because both processes use vibratory energy to weld plastic assemblies. However, both processes are very different from each other. Let’s look at the differences between the two processes and how you can use them to your advantage.

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Hybrid welding and 4 reasons why you might need it

Hybrid welding and 4 reasons why you might need it

Have you heard the news? Extol recently partnered with CEMAS to distribute their vibration and hybrid welding machines in the US and Canada. We are thrilled to now be able to offer our customers even more plastic joining options as well as top of the line vibration and hybrid welding equipment, service, and support. Now just in case you’re thinking, “I know about vibration welding, but what is this hybrid welding thing you mentioned?” we’re going to dig into it a bit and explain why it might be a great option for your project.

read more

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