Impulse welding
Impulse welding joins compatible thermoplastic materials using a heated welding bar and pressure. An electrical pulse heats the element, which transfers heat to the seam. The joint then cools under pressure. Forsstrom impulse welding machines help manufacturers produce controlled seams in films and coated fabrics for products such as covers, industrial doors and shading systems.
What materials can be impulse welded?
Impulse welding can join suitable PVC, thermoplastic polyurethane (PU/TPU), polyethylene (PE) and polypropylene (PP) films and coated fabrics. Some laminates and technical textiles can also be joined with a compatible weldable layer or bonding tape. Material construction, thickness and heat response determine the settings. Forsstrom can help evaluate your samples and select a suitable welding setup.
Advantages of Impulse Welding in Thermoplastic Welding
Controlled heating cycles
Heat is applied during the programmed heating phase rather than keeping the welding element continuously hot. Heating and cooling times can be matched to the material and seam requirements.
Repeatable seam quality
A defined welding cycle helps reproduce seam quality across production runs. The combination of heating, pressure and cooling is set for the material, with control options depending on the machine configuration.
Strong, sealed joints
Impulse welding can create strong, watertight or airtight seams in suitable materials. The material combination and welding settings must be validated against the finished product’s performance requirements.
Versatile material joining
Impulse welding can join suitable thermoplastics that do not respond to HF energy, including PE and PP. It also supports coated fabrics and selected laminates with a compatible welding setup.
Long seams in one cycle
A welding bar joins the seam along its working length in one cycle. Different bar lengths, widths and guides support overlap seams, hems and pockets, depending on the machine and tooling.
How does impulse welding work?
Impulse welding combines a timed heating pulse, pressure and cooling in five steps.
Position the material
Align the material layers beneath the welding bar using the guides required for the seam.
Close the welding bar
The bar presses the layers together to maintain contact along the weld area.
Apply the heating pulse
Electrical current heats the element, transferring heat through the bar to the material.
Fuse the layers
The weldable surfaces soften and fuse under the selected heating and pressure conditions.
Cool and release
The heating pulse ends. The seam cools under pressure before the bar opens.
Who uses impulse welding?
Manufacturers use impulse welding for industrial doors, covers, tarpaulins, blinds, awnings and other shading products. Suitable material combinations also support tents, inflatable products and containment applications. Share your material, seam dimensions and production volume with Forsstrom to discuss the iP, iM or iG impulse welding machine series.