Impulse Welding

Impulse welding is the process by which electricity is used to create heat through a high resistance wire. The wire is typically nickel-chromium encapsulated in a non-stick coating. A current will cause the wire to heat rapidly which is transferred to the materials.  Traditional impulse welding processes have limited controls over the heating and cooling cycles. This results in a continuous heat build-up as the machine cycles, negatively effecting the repeatability of subsequent welds.


Dielectrics has developed a proprietary system with a closed loop feedback that enables control over the entire weld cycle. The process automatically compensates for variables in the materials, environment, and current fluctuations thus delivering an accurate and repeatable target temperature.  Dielectrics continues to apply this process to new engineered materials that cannot be traditionally RF welded.  


  • Quick welding cycle
  • No weld bead
  • Peelable seals


  • Lower seal bond strength compared to other welding techniques
  • Only usable on thin films (<0.02")
  • Limited design freedom and size