NEWS RELEASE: Dukane servo ultrasonic welding with Melt-Match® advances wearable glucose monitoring device production
[Photo courtesy of Dukane]
The project began in 2018 as the manufacturer was developing a new connected device designed to support glucose monitoring and insulin delivery technology. As a wearable medical device containing internal electronic components, the product required a welding process capable of delivering strong, consistent bonds while protecting sensitive internal assemblies.
The application involved four ultrasonic welds in total, including three staking welds and one housing weld to join the two halves together. Because the device needed to be hermetically sealed, the welding process had to provide a high level of precision, repeatability, and control.
Dukane became involved early in the development process through an existing industry relationship. This connection allowed Dukane and the manufacturer to begin evaluating the application during the early stages of product development.
At the time, Dukane was uniquely positioned to support the application through its servo-driven ultrasonic welding technology. The manufacturer required a process that could meet demanding medical device manufacturing requirements while maintaining the speed and efficiency needed for production.
The solution centered on Dukane’s servo-driven ultrasonic systems with Melt-Match® technology, applying 40 kHz ultrasonic energy across all four required bonds. The 40 kHz frequency helped address the delicate nature of the assembly, allowing ultrasonic energy to be delivered with the precision needed to protect sensitive internal components.
Throughout the development process, Dukane and the manufacturer worked closely through multiple stages of evaluation, testing, and refinement. The collaboration allowed both teams to assess the weld requirements, review process performance, and make adjustments as the product moved from concept to production.
The patented Melt-Match® technology provided the level of control needed for the application, including precise management of weld motion, force, and energy delivery. This was especially important for protecting the internal electronics while achieving the weld quality required for a wearable medical device.
The result was a repeatable and scalable joining process capable of meeting demanding requirements for precision, sealing, and production performance.
Following years of development and collaboration, the product received regulatory clearance, marking an important milestone for the connected diabetes management platform and the manufacturing process behind it. Today, Dukane’s ultrasonic servo technology continues to help medical device manufacturers bring advanced, connected healthcare products to market.
About DUKANE
DUKANE, headquartered in St. Charles, Illinois, is an award-winning leader in laser and ultrasonic technology with a customer-centric approach to innovation. The company develops solutions tailored to the unique requirements of each customer’s application. As a global organization, DUKANE offers one of the world’s most extensive plastic welding portfolios, with international support available 24 hours a day. Serving major industries including automotive, medical, electronics, packaging, nonwovens, food, automation, and cutting, DUKANE brings more than 100 years of technological experience to every solution. The company operates facilities and offices through-out North America, Europe, and Asia. Learn more at dukane.com and connect with DUKANE on LinkedIn, X, and Facebook.
The opinions expressed in this news release are the author’s only and do not necessarily reflect those of Medical Design & Outsourcing or its employees.
