What is RF (High Frequency) Welding?

Our newest innovation, the FlexShield Packaging Pouch, is manufactured via RF welding

Our Medical Instrument Packaging Pouches Made From FlexShield Thermoplastic Polyurethane Film (TPU)

Radio frequency welding or (high frequency welding) is the process of bonding together materials through the use of electromagnetic energy. Two electrodes create an oscillating electric field that begins to shift and move polar molecules within the materials in order to orient themselves in accordance with the electromagnetic field. The movement of these molecules releases energy in the form of heat. When enough energy is applied, the molecules begin to melt and bond to one another. No external heat is applied. The weld is completed by applying pressure to the bonded area, ensuring a successful seal.

 

 

What Factors Contribute to a Good Weld?

Many factors affect the strength and seal quality in RF welding. Tooling layout, weld thickness, material thickness, and machine control are some of the most important factors in creating a good seal. The appeal of RF welding is in the completeness of the weld. Using this method can create very robust hermetic seals. Many welds are subject to pull tests, leak tests, and optical tests to determine that the correct conditions have been achieved.

 

What Materials Can Be RF Welded?

Some materials are more of a challenge to RF weld than others and may even require a special process. No matter the level of difficulty, UFP Technologies is confident in its ability to expertly perform RF welding on the following materials:

  • PET
  • PETG
  • PVC
  • Thermoplastic polyurethanes (TPU)
  • Open Celled Polyurethanes
  • LDPE/EVA

 

Why Use RF Welding?

There are several alternatives to RF welding including sewing, gluing, or using hot air. Why use RF welding?

RF Welding vs. Sewing

RF welding provides a consistent air tight seal unlike sewing. When sewn seams are stressed, the thread takes the pressure and could break. RF welds evenly distribute stresses throughout the material providing a much stronger seam while preventing any air, moisture, or debris getting in.

RF Welding vs. Gluing/Adhesives

Gluing can provide an air tight solution, but gluing takes much longer than RF welding and often uses hazardous solvents that are harmful to the environment. Glued seams are also subject to failure once the adhesive has worn out.

RF Welding vs. Hot Air

Hot air is a method that applies heat to the outside of the material to melt it and create a bond. This method is only effective up to certain thicknesses. Materials that are too thick will not bond in the middle as the core will struggle to melt, while the outside layers are over heated or burned. RF welding heats from the inside out and is the best method for forming air tight seams.

 

UFP Technologies’ RF Welded Products

RF Welded FlexShield Packaging Pouch For Medical Instruments

Our RF Welded Packaging Pouch Made From FlexShield TPU For Medical Instruments

Our packaging pouch made from FlexShield® thermoplastic polyurethane film (TPU) is one of our newest innovations for the medical device industry. The FlexShield® TPU pouch is manufactured via RF welding and provides puncture and abrasion resistance in order to safely ship medical instruments without incurring damage to external packaging. Utilizing FlexShield pouches within your packaging systems will ensure the integrity of the sterile barrier between your instruments and outside contaminates.

It is crucial to the functionality of the product that the RF welds on the FlexShield pouch maintains integrity throughout the supply-chain. RF welding is also used in a number of wound care applications that assist patients through the healing process. For safe storage of defibulators, UFP Technologies manufacturers a three chamber reusable pouch storage system that is sealed using RF welding. We also utilize these capabilities to produce industrial cleaning products.

 

Why UFP Technologies?

In February 2018, UFP Technologies acquired Dielectrics, Inc., a leader in the design, development, and manufacture of medical devices using RF welded thermoplastic materials. Our combined capabilities and expertise allow us to provide improved patient outcomes by minimizing the chance for infection, improving patient comfort, and promoting faster healing. To learn more about Dielectrics visit their website at www.dielectrics.com.

8 thoughts on “What is RF (High Frequency) Welding?

    • Hi Dominic,

      Thanks for checking out the blog, hope you found the information useful. Please send your project details over to info@ufpt.com and we’ll determine if we can assist you.

      Thanks!

  1. I am looking at a process where I wish to attach a polyimide film (thermoset material) to an epoxy glass substrate (FR-4). Am told that ultrasonic weld will not work. Will RF Weld hold in acids, bases and temps up to 170F?

    • Hi Chuck,

      Thanks for checking out the blog, hope you found the information useful. Please send your project details over to info@ufpt.com and we’ll determine if we can assist you.

      Thanks!

  2. I am looking for a high volume RF welding operation for an open-cell polyurethrane medical grade foam to a polypropylene base. The foam applicator is 1 1/4″ round and 1/2″ thick to a 1″ round plastic base.

    • Hi Dana,

      Thanks for checking out the blog, hope you found the information useful. Please send your project details over to info@ufpt.com and we’ll determine if we can assist you.

      Thanks!

    • Hi Clinton,

      Thanks for checking out the blog. A UFP representative will be in contact with you as soon as possible.

      Thanks!

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