Why You Should Choose Radio Frequency Fabric Welding Over Impulse Welding

April 8, 2022

Radio Frequency Fabric Welding often involves heat sealing materials by applying radio frequency to the area you are joining. In RF welding, the heating process takes place from the inside out. Industries that create straight or uniquely shaped products rely on radio frequency welding for most of their operations.

How does RF Welding Work?

Radio Frequency (RF) welding relies on high frequency electromagnetic energy (HF) to complete material fusion. In this process, you will subject the parts you want to join to a high-frequency electromagnetic field. Radio frequency (RF) and high frequency (HF) are terms that are used interchangeably depending on what continent you are on.

Before welding begins, the electromagnetic energy creates an alternating electric field between two metal welding bars. These bars will also serve as pressure applicators during heating or cooling. The created electric field makes polar molecules oscillate and take an orientation that resonates with the electromagnetic field. The oscillation takes place at 27.1 MHz or 27.1 million times per second.

Over time, usually 4 to 12 seconds, this process generates energy that will increase the temperature and cause materials to melt. A weld will form when you clamp the welding bars to apply pressure on the bars. This process will form a molecular weld with the right combination of energy, time, and pressure.

With RF welding, industries can create consistent straight welds like billboards or tarpaulins. Also, this welding technology is ideal for creating unique shapes like water tanks, oil booms, and tent peaks. Here is why you should choose radio frequency fabric welding over impulse welding.

Impulse welding is usually used for window shades and other light industrial material applications.  Because heat needs to travel through a top panel and through the second panel, thicker materials are not advised with Impulse welding.  Further, the welding time with impulse technology is quite significant as compared to RF welding technology.

Dramatically Decreases Weld Times

Radio Frequency welding delivers fast cycle times that ensure that you spend less time welding. Also, this process allows you to localize heat, increasing the overall welding speed significantly. The radio frequency excites molecules, increasing their movement and creating heat. Internal heat melts the polyurethane, which then fuses the materials.

Continuous heat supply ensures that you maintain a consistent welding process. The fusion process also takes place quickly, given that RF welding heat seals the material from inside out.

Besides minimizing your weld times, RF welding allows you to control operations proactively. This capability helps you cool down and heat the welding machine in the shortest time possible. Use less energy on your welding project while saving considerable time.

Weld Different Shapes with Tooling

The RF process works suitably for diverse thermoplastic materials which have polarized molecules. RF welding will work suitably with polyurethanes and polyvinyl chloride material. The extended versatility of RF welding has made it a firm favorite among numerous clients. Weld your fabrics with diverse thicknesses, chemical makeups, and colors. Besides, you can create unique shapes and seals with this welding technique.

You could use tooling to localize heating during dielectric sealing. Ultimately, you'll have a seamless area with a stronger bond than the original material. Once you complete welding, you can finish your welded product to your specifications. RF welding can help you seal air-filled products. This process lets you destabilize the surfaces' thickness before applying pressure to create a new, fused seam.

Use custom-made tooling dies to create your product's shape and functionality. You could also use specialized dyes when you need to create intricate welds. RF welding will typically perform well. RF welding also delivers extended versatility, especially when welding polyurethane material.

Weld Multiple Fabric Layers Easily

In RF welding, you’ll place materials that require welding between sealing dyes before you begin the welding process. Given that heating occurs from within, you can weld layers of material with ease. Essentially, once you place the molecules in place, pressure from the electrodes allows you to create a permanent seam with no trouble.

You can also use radio frequency welding to weld polyurethane with another material, like vinyl. Remember to check the compatibility of this process. With RF welding, you will have a product that keeps unwanted substances out. You’ll also have an easier time welding patches and support straps using RF welding.

Weld Over Already-Welded Material

RF welding lets you hit already-welded areas more than once, unlike other welding processes. Besides, there will be no risk of poking holes or causing damage to the fabric you use. Make the most of specialized dies when you need to create intricate welds.

This advantage of high frequency welding ensures that you create stronger seams that can fit in diverse manufacturing projects. You won't need adhesives or by-products when using RF welding. This process combines time, RF energy, and pressure to create a robust, uniform weld throughout the seal.

The comprehensive process ensures that the weld seam remains stronger than any surrounding material. Overall, you’ll end up with an airtight and waterproof weld.

Ability to Weld Curves and Radiuses

Do you want to add a personal, decorative touch to your product? RF welding will not disappoint you. You can engrave the welding tool and use it to decorate your product. The welding process creates stronger welds with watertight seams that last as long as the material. 

RF welding enables you to weld curved shapes and any difficult areas where impulse welding may have restrictions. Stay updated on the latest developments in RF welding by visiting our blog. Radio Frequency welding is ideal for medical device manufacturing thanks to its versatility.

With this process, manufacturers can create robust leak-proof seals for wound care devices, patient warming products, and fluid pouches. RF welding is ideal for creating heat sealed military applications like safety products, protection gear, and hydration pouches.

Applications of Radio Frequency Welding

Different industries make the most of the advantages of radio frequency welding. Common applications of this technology include:

  • Medical plasma bags

  • Vinyl banners and signage

  • Industrial-use curtain walls

  • Vinyl binder covers

  • Transportation blister packs

  • Transportation upholstery trimmings

  • Tents

  • Tarpaulins and covers

It is usually helpful to use radio frequency welding when producing items in high volume. Machines used in this process require unique resetting for every new item produced. Therefore, you will achieve more and leverage the technique's full potential when using it for mass production. Essentially, if you are only welding items on a one-time basis, radio frequency welding might not offer a practical option.

Find Top-Notch Radio Frequency Welding Solutions

Overall, RF welding offers multiple advantages over impulse welding. This process also offers a more versatile and efficient welding process for your diverse welding needs. Save time and money whenever you select this cost-efficient welding process.

Do you need help selecting the best welding technology for your application? Talk to our Miller Weldmaster experts, and we will guide you on the welding technology that will deliver maximum results for your project. Let us test your materials on our machines, then offer guidance on the welding technology that won't disappoint.

We offer high-performance welding solutions that guarantee precision and versatility. Save time and money while using our radio frequency welding technology. Contact us today to find help in determining the technology and machine suitable for your production.

Topics: Radio Frequency

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