Comprehensive Engineering Solutions for Modern Manufacturing
At Invictosonics Engineering LLP, we deliver end-to-end solutions in plastic welding, automation and custom machine development, designed to improve efficiency, precision and productivity.
1. Plastic Welding Technologies
At Invictosonics Engineering LLP, we provide a complete range of plastic welding technologies designed to deliver strong, reliable and precision-engineered joints across various industries. Our expertise ensures the right welding process is selected based on material, part geometry, strength requirement and production volume.
Vibration Welding
Frictional heat generated by relative motion between two thermoplastic parts under pressure. One part is held stationary (fixed platen) while the other vibrates laterally at controlled frequency. Available in linear (120/240 Hz) and orbital variants — process phases: Solid Friction → Transient Flow → Steady-State Flow → Cooling.
Key Parameters:
- Frequency: 120 Hz (low) / 240 Hz (high)
- Amplitude: 0.7 mm to 1.8 mm peak-to-peak
- Weld Pressure: 0.5 to 10 MPa
- Clamp Force: 1 kN to 50 kN | Platen: up to 800 x 600 mm
- Cycle time: 8 to 30 seconds | Multi-head configurations available
Applications:
- Automotive air intake manifolds, fluid tanks
- HVAC ducts, battery enclosures (EV)
- Bumpers, battery trays, structural components (GF up to 50%)
- Large industrial components — weld areas up to 800 x 600 mm
- Hermetic seals for fluid-tight and gas-tight applications
Hot Plate Welding
Thermoplastic parts heated by direct contact with a heated platen (200–350°C), then pressed together under controlled force. Hot plate temperature is typically 20–80°C above material melting point. Servo-driven platens ensure precise control with changeover time under 3 seconds. Weld strength 80–95% of base material.
Process Sequence:
- Load Parts → Heating (melt layer forms) → Changeover (<3 sec)
- Joining (molecular chains intermix) → Hold/Cool (solidification)
- PTFE/Teflon coated hot plates | Multi-zone temp control (±2°C)
- Non-contact IR variants available for delicate parts
Applications:
- Tail lamp assemblies, fluid reservoirs, battery housings
- Washing machine tubs, dishwasher components, water heater tanks
- HVAC ducts, large 3D weld geometries — complex curved profiles
- Suitable for HDPE, PP large parts difficult to weld otherwise
- Particulate-free welding with non-contact (IR) variants
Ultrasonic Welding
High-frequency mechanical vibrations (20 kHz or 35 kHz) applied perpendicular to joint interface. Electrical energy converted via piezoelectric transducer → booster → sonotrode to generate intermolecular friction and melt thermoplastic at the joint. Weld forms in 0.1 to 2 seconds — fastest plastic welding technology available.
System & Parameters:
- Frequency: 20 kHz (standard) / 35 kHz (fine) | Amplitude: 20–120 microns
- Generator: 500 W to 6,200 W | Weld Force: 50 N to 5,000 N
- Sonotrode materials: Titanium / Aluminum / D2 Steel
- Weld modes: Time, Energy, Distance, Power
- Clean process — no fumes, no consumables, minimal flash
Applications:
- Medical: filters, IV spike ports, diagnostic cartridges (cleanroom)
- Electronics: battery packs, PCB enclosures, connector assemblies
- Automotive: sensor housings, connectors, trim clips, light guides
- FMCG: packaging seals, razor cartridges, pen caps, toy assemblies
- Hermetic and particle-free welds for medical and electronic applications
Spin Welding
One part rotates at 1,000–15,000 RPM while the other is held stationary; friction generates heat at the circular joint interface. Axial force applied simultaneously; rotation stops abruptly and molten material solidifies under continued axial pressure. Available in inertia and direct-drive variants — ideal for circular or cylindrical parts.
Key Parameters:
- Speed: 1,000 to 15,000 RPM | Axial force: 100 N to 20,000 N
- Weld time: 0.5 to 5 seconds — very fast, high-volume suitable
- Servo motor drive with angular position control (±2°)
- Multi-station rotary table integration | Quick-change tooling
- Strong hermetic seals — burst pressure exceeding parent material
Applications:
- Automotive: oil filters, coolant reservoirs, PCV valves, round fluid connectors
- Consumer: water bottles, cosmetic containers, aerosol cans, pen barrels
- Medical: syringe housings, catheter hubs, filter housings
- Marine: underwater connectors, sealed enclosures
- Materials: PP, PE, PA, POM, ABS, PC — all weldable by spin
Custom Tooling for All Processes
Tooling is the interface between the welding machine and the customer's part — directly determining weld quality, cycle time, and repeatability. INVICTOSONICS provides complete in-house tooling design and manufacturing with rapid prototyping and iterative optimization for new applications.
Tooling by Process:
- Vibration: Upper/lower fixture plates, part nests, flash trap features, clamp mechanisms (Aluminum/Steel)
- Hot Plate: PTFE-coated heated tool plate, multi-zone heater cartridges, thermal insulation plates
- Ultrasonic: Sonotrode (Titanium/Aluminum/D2 Steel), fixture/anvil, booster selection
Design Best Practices:
- Full part support — no deflection under weld force
- Precision locating features — datum surfaces, guide pins, reference edges
- Flash traps and clearance zones to capture weld flash
- Quick-change capability for multiple part variants
- Replaceable wear inserts at high-contact points
2. Automation & Engineering Solutions
At Invictosonics Engineering LLP, we provide advanced automation and engineering solutions designed to optimize manufacturing processes, improve accuracy and enhance productivity. Our automation systems are custom-designed and fully integrated, enabling seamless coordination between assembly, inspection, and material handling operations.
Assembly Automation Lines
Custom-designed assembly automation integrating pick-and-place, press-fit, screw driving, clip insertion and dispensing operations into a single workflow. Built with Siemens/Mitsubishi PLCs, servo drives and HMI touchscreens for precise, repeatable, high-volume production with minimal operator intervention.
Applications:
- Automotive component assembly
- Electronics product assembly
- Medical device manufacturing
- FMCG product assembly lines
- Multi-station industrial assembly systems
Leak Testing & Inspection Systems
Advanced leak testing using pressure decay, mass flow, helium leak detection and differential pressure methods. Integrated with vision inspection, laser marking and traceability systems (barcode/QR/RFID) to ensure components meet strict quality and safety standards.
Applications:
- Automotive fuel tanks and fluid systems
- Medical devices and fluid components
- Packaging and container testing
- Appliance water systems
- Industrial pressure systems
Vision Inspection Systems
Cognex and Keyence-based 2D/3D vision systems performing real-time inspection, barcode reading and assembly guidance. Integrated with PLC for automated pass/fail decisions, data logging and OEE tracking for full traceability across production.
Applications:
- Electronics PCB inspection
- Label and packaging verification
- Automotive component inspection
- Medical device quality checks
- FMCG product inspection lines
Conveyor & Material Handling Systems
Multi-station rotary systems, linear transfer lines, and conveyor-based flow lines with robot-integrated cells (YASKAWA, ABB, FANUC, KUKA). Industry 4.0 connectivity for OEE tracking, VPN-based remote diagnostics, and recipe management for multi-part production.
Applications:
- Assembly line material movement
- Packaging and sorting systems
- Warehouse automation
- Automotive and electronics production
- FMCG manufacturing plants
3. SPM Design (Special Purpose Machines)
At Invictosonics Engineering LLP, we specialize in designing and manufacturing Special Purpose Machines (SPMs) — custom-engineered around the customer's part and process. Each SPM undergoes rigorous FAT (Factory Acceptance Test) before delivery. Typical project timeline: 12 to 20 weeks from design freeze to commissioning.
Custom Machine Design
SPMs custom-engineered around the customer's part and process — combining welding, assembly, testing, and inspection in one system. Project lifecycle: RFQ → Concept Design → Detail Engineering → Manufacture → FAT → SAT at customer site. Timeline: 12–20 weeks from design freeze to commissioning.
Applications:
- Automotive component manufacturing
- Plastic welding systems
- Assembly and production lines
- Custom industrial processes
Multi-Station Systems
Multi-station rotary and linear transfer systems integrating welding, assembly, leak testing, vision inspection, and marking into a single automated cell. Balanced station design for optimal UPH with capability studies (Cp/Cpk) and run-at-rate validation before delivery.
Applications:
- Multi-step assembly operations
- Automated production lines
- Testing and inspection stations
- High-volume manufacturing setups
Servo-Driven Mechanisms
Servo motors with ball screws and linear actuators for precise motion control across all axes. SMC and Festo pneumatic systems for grippers, rotary actuators, and vacuum generators — integrated with PROFINET, EtherNet/IP, and EtherCAT fieldbus communication.
Applications:
- Precision assembly systems
- Welding and insertion processes
- Automated positioning systems
- High-speed production machines
PLC & HMI Programming
Siemens S7-1200/1500, Mitsubishi, and Delta PLCs with 7–15 inch HMI touchscreens. Features: cycle data logging, traceability, OEE monitoring, VPN-based remote diagnostics and recipe management for multi-part production.
Applications:
- Automated production lines
- Machine control systems
- Monitoring and diagnostics
- Smart manufacturing setups
Safety-Compliant Designs
Safety PLC/relays (Category 3/4) with light curtains, safety laser scanners, two-hand start controls, and guard locking interlocks. Emergency stop circuits per EN ISO 13849, risk assessment per ISO 12100 — all machines CE/UKCA marked and compliant.
Applications:
- Industrial manufacturing units
- Automated production lines
- High-speed machinery environments
- Compliance-driven industries
Ready to Explore?
Explore our innovative machines and products designed for excellence.
Address: Plot no. – PAP G34, Chakan Indl. Area,
Phase II, Savardari, Tal-Khed,
Pune-410501, Maharashtra, India
Phone: +91 96194 43552
Business Hours: Monday to Saturday, 9 AM – 6 PM