There are numerous terms that define the process of rf fusing flexible materials together. Radio frequency welding, high frequency welding and dielectric welding (also referred to as dielectric sealing) are all used to describe this process and they accomplish the same results, welding similar or dissimilar flexible materials together to form a nearly impenetrable bond.
What is Radio Frequency Welding?
Also known as high frequency welding and dielectric sealing, this manufacturing process uses electromagnetic energy and pressure to weld and permanently bond thermoplastic, vinyl and coated fabrics to create a dimensional product. The rf sealing process is most often referred to as radio frequency welding because of the way the electrostatic energy and pressure are used to realign the molecules to form a new, strong bond of the materials being fused together. Using this rf seal service, a new, one-piece permanent bond is created that is impenetrable and resistant to tearing.
How RF Welding Works
The radio frequency welding process scrambles the molecules in flexible polymeric materials to be joined for the dimensional requirements and product functionality. RF welding is a three-step process involving the preparation and positioning of the components, adding of electromagnetic energy and pressure to molecularly combine the materials, and finally, the cooling of the materials.
When cooled, the newly formed seam is as strong or even potentially stronger than the original material. The RF welding process can only be used with materials of a polar molecular construction, the most common being PVC and Polyurethane, although many other coated materials such as nylon are feasible. RF sealing works much better with stretchable unsupported film type materials such as TPU and TPE type materials. Other commonly welded materials are EVA, PET and PETG.
Find more information about Material Selections for the RF Welding process.
Choosing the Right Sealing Process
The best sealing process for any product application is usually determined by the materials being used, the product size and configuration, and the quantity to be manufactured. The fusing of many types of flexible materials through radio frequency sealing is a reliable option for creating sealed, leak-proof bonds on products used in medical, military and industrial applications. RF, HF and dielectric welding processes offer consistency in reproducing elements under clean conditions, without the use of messy adhesives or solvents.
Our Sealing Processes Create Dimensional Shapes
The materials to be welded are placed between the upper and lower tooling (electrodes) which are positioned between the machine bed on the bottom and the platen on the top. This is where the electromagnetic current is directed and the pressure is applied during the RF welding process. This radio frequency energy agitates and heats the materials causing them to melt together. The tooling die or working surface is where the shape of the product is created, as the electrodes simultaneously shape the weld to the tooling die, and the electromagnetic energy fuses the combination of materials to form the bond.
Find out more about using Tooling Dies to create product functionality.
Talk to our RF Welding Experts
SealWerks provides the best heat sealing method to meet your product’s functionality requirements. We can help with material selection, welding options and design assistance to complete or improve your finished product. Call us Today at 877-713-4209.