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Ultrasonic Plastic Welder PR-28U

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ULTRASONIC PLASTIC WELDER

Fast, portable solution for repairing and welding bumpers, brackets, and automotive plastic components. Ultrasonic technology provides instant, strong bonds without filler materials or preheating time.
PR-28U converts electrical energy into high-frequency vibrations (28.5 kHz). Combined with clamping pressure, these vibrations generate heat that fuses compatible plastic materials together.

Ultrasonic Plastic Welder Brochure - 1.7 MB

Component List - Coming Soon

Manual - Coming Soon
  • Ultrasonic Joining: Restores small brackets, mounts, clips, tabs, and trim without adding visible filler mass or extensive heat distortion.
  • Power Reserve: Operates at 28.5 kHz with >800 W electrical power, offering over 33% more energy than typical 600 W / 40 kHz competitor systems for demanding thermoplastics.
  • Process Qualification: Complements nitrogen/hot-air welding; does not universally replace OEM repair procedures or guarantee blanket approval.

Applications

  • Collision Repair Applications: Parking-sensor (PDC) holders, blind-spot detection (BSD) / radar brackets, grille/air-intake attachments, headlamp tabs, bumper clips/rivets, interior door/trim mounts.
  • Assembly Applications: Interior door panels, instrument subassemblies, center consoles, housing covers, prototype/low-volume fixtures.
  • OEM Example: Replacement bumper covers often do not come with pre-welded sensor mounts. Localized ultrasonic welding installs new mounts precisely without excess filler that could distort sensor seating or the decoupling ring.
Ultrasonic Plastic Welding application

 



 Material Energy Requirements:

  • Amorphous Plastics (ABS, PC): ~200 W at 1 mm up to ~1,000 W at 5 mm.
  • Semi-Crystalline Plastics (PP, PA): ~400 W at 1 mm up to ~2,000 W at 5 mm (requires ~2x the power of amorphous materials).

Optional Sonotrodes (Horns)

Quick and easy to change, optional sonotrodes screw directly onto the handpiece’s transducer/booster assembly. Their threaded design allows for fast, tool-free installation and replacement by hand, making it easy to switch between different welding applications.



Ultrasonic Plastic Welding attachments

  • #1 to 5:Primarily designed for standard plastic repair (e.g., crack mending, fusing two pieces of the same thermoplastic material together).
  • #6 to 8: Used for attaching new plastic elements onto existing components. For example, #7 is frequently used in body shops to weld parking sensor brackets onto replacement bumpers.
  • #11 to 13: Specialized for heat-staking / flattening plastic pins and rivets to secure components together. For instance, #13 is commonly utilized in OEM-style procedures (such as by Stellantis) for securing bumper grilles.
  • #14: Used for structural welding of larger or specific multi-component plastic assemblies. For example, #14 (and similar variants in this range) is often applied when joining the plastic inner panels that support speaker housings inside vehicle doors.


 

Ultrasonic Joining vs Nitrogen Welding Comparison 

Criterion Ultrasonic Joining Hot-Air / Nitrogen Welding
Primary Mechanism Localized frictional heating & pressure at joint interface External heating and fusion with compatible filler rod
Best Suited For Small brackets, sensor mounts, clips, rivets, bosses, tabs Cracks, tears, missing sections, large surface rebuilds
Filler Material None required for compatible mating parts Requires compatible plastic filler rod
Heat Exposure Concentrated at contact sonotrode area Broader thermal zone around weld bead
Surface Finish Clean, localized weld with minimal build-up Weld bead requires grinding, sanding, refinishing


 

Technical Specifications

Power Supply: 110V AC ±10% / 60 Hz
Plastic Compatibility: PP, ABS, PC, PE, PA & Blends
Operating Frequency: 28.5 kHz (28–35 kHz Range)
Peak Power Output: >800 W High-Reserve Output
Weld Operating Modes: Timed Pulse & Continuous
System Net Weight: ~14.3 lbs (~6.5 kg)
 


 

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