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How Hardware Startups Use Ultrasonic Welding for Fast Assembly
In this episode of Hardware Startups with Fexingo, Lucas and Luna dive into ultrasonic welding, a high-speed assembly technique that bonds thermoplastics in under a second without glue or fasteners. They explore how a startup called SoundBond — a real company making rugged IoT sensors — cut their enclosure assembly time from 90 seconds per unit to 3 seconds by switching from screws and gaskets to ultrasonic welding. Lucas explains the physics: 20 kilohertz vibrations create frictional heat at the joint interface, melting a molded energy director. Luna notes the trade-off: upfront tooling…
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