3D Welding

3D Welding is a combination of tool design and process technique that allows for complex, 3D shapes to be thermally welded even if they are in their final shape. Traditionally, RF was only used on flat shapes, which then needed to be inflated, folded, or bent into the desired shape. This resulted in wrinkles and creases in the product, thus limiting product utility and aesthetics.

See the Case Study,  Sunrise Medical.

The technique converts complex 3D splines into small, RF-weldable sections.  Using this technique even features like undercuts can be created.

Benefits

With traditional RF techniques, the welds generally end up outside the perimeter. Since these welds tend to be stiffer than either of the substrates alone, they can create abrasive surfaces or stress risers. With 3D welding, those welds can be situated in less objectionable areas of the product.