Ultrasonic Welded Outdoor Light Housing

Ultrasonic Welded Outdoor Light Housing – Precision Injection Molding & Sealed Assembly for Harsh Environments

Ultrasonic welding is the industry-preferred joining method for outdoor lighting because it provides:

1. Superior Waterproofing (IP54–IP67 Ready)

The welding horn melts the joint line without adhesives, creating a continuous molecular bond that prevents water, dust, and humidity from entering the LED chamber.

2. Strong Mechanical Strength

The joint is as strong as a single molded part-ideal for portable work lights, headlamps, bike lamps, and other products exposed to impact or vibration.

3. Fast and Clean Assembly

No glue curing time, no chemicals, no VOC emissions. Perfect for mass production and environmentally compliant assembly lines.

4. High Dimensional Precision for Optics

Critical for parts involving:

• Reflector alignment
• TIR lenses
• Transparent front covers
• Diffuser and LED PCB spacing

Ultrasonic welding keeps optical tolerances consistent batch after batch.

Benma's production workflow is optimized for engineering plastics commonly used in outdoor illumination:

Common Materials

Molding Capabilities

Two-shot molding (hard + soft material, waterproof buttons)

High-gloss and matte surface mold textures (VDI / SPI)

Insert molding for metal heat sinks

Precision molds with ±0.03–0.05 mm tolerances

Our in-house tooling team designs mold flow, gating, draft angles, and welding ribs specifically to ensure optimal welding strength and low deformation.

Each product is engineered with energy directors-small triangular ribs that melt instantly during welding.

Standard Workflow

Inspection of molded parts (warpage, size, flash, transparency)

Fixture positioning to ensure optical alignment

Welding parameter setting

Frequency: 20 kHz / 28 kHz

Pressure: 1.2–3.0 bar

Amplitude stroke: 20–60 μm

Welding cycle: 0.3–0.8 seconds

Cooling phase to stabilize joint

Post-inspection: sealing, strength, cosmetic checks

IP Water Resistance Testing

We perform optional waterproof tests:

• Air leakage test
• IPX4–IPX7 spray test
• Submersion test

This ensures every welded enclosure meets the client's environmental durability requirements.

Benma Electric is ISO9001 & SMETA certified, and our QC workflow includes:

Incoming material inspection

Resin certifications

Optical grade testing for PC

Silicone hardness and color tolerance

In-process control

CPK for critical dimensions

Welding strength sampling

Surface inspection under high-lux environment

Burr & particulate control for lenses

Final product validation

Drop tests

UV aging tests

Waterproof tests

Assembly fit tests with PCB and LED modules

Our objective is simple: zero-defect enclosures ready for your assembly line.

Our vertical integration allows clients to consolidate suppliers and reduce cost and lead time.

Suitable for:

Any product requiring sealing, toughness, and long-term reliability benefits from ultrasonic welded housings.

We support:

Contact us today to receive drawings analysis, cost estimation, and manufacturing suggestions within 24 hours.

BMA

Benma Electric Co., Ltd. offers a full range of injection molding services, including mold design, manufacturing, and plastic part production. With an expert technical team and advanced in-house tools, we ensure high-performance parts used in industrial machinery, outdoor lighting, and electronic consumer goods.

Mold

Workshop

Processing Workshop

Material

Warehouse

Hardware

Workshop

Assembly

Workshop

Laboratory

 

A zoned workshop layout supports continuous operation and enhances control over each production stage.

With cutting-edge equipment, our workshop maintains accurate manufacturing and uninterrupted operations.