Manufacturer of ultrasonic, laser, vibration, spin and hot plate welding systems for plastic and metal joining
Dukane IAS, LLC
St. Charles, IL (USA) · Kimberly, WI (USA) · Buford, GA (USA) · Wixom, MI (USA) · Santa Catarina, Querétaro (MX) · Prague (CZ)New on Amplifa
About Dukane
Dukane is a privately held manufacturer of plastic and metal joining technologies, founded in 1922. The company develops and manufactures servo-controlled ultrasonic welding systems (Infinity™ with Melt-Match®, iQ Servo), 6000-series vibration welding machines, laser plastic welding platforms, infrared, spin (Servo Weld™ Plus) and hot plate welding systems (Thermal Hybrid) as well as ultrasonic modules for metal welding (SynQro™ Quadro). At its headquarters in St. Charles, Illinois, Dukane operates its own CNC machine shop for tool and horn (sonotrode) manufacturing from materials such as aluminum and titanium. Fields of application include automotive, medical technology, packaging, electronics, nonwovens and hygiene, food processing and EV battery manufacturing, for example wire-to-busbar connections made of copper and aluminum. In addition, application laboratories offer feasibility testing, tool design with 3D FEA, training, service and support. Alongside locations in the USA and Mexico, Dukane maintains a Technical Center in Prague for Central Europe.
- Site
- St. Charles, IL, USA
- Processes
- Servo Ultrasonic Welding, Vibration Welding, Laser Plastic Welding, Infrared Welding (contactless), Spin Welding, Hot Plate Welding, Ultrasonic Metal Welding, Ultrasonic Cutting
- Materials
- Copper, Aluminum, Polycarbonate, Thermoplastic resins (rigid and flexible), Titanium (horn material for ultrasonic cutters), Titanium
- Certificates
- ISO 9001:2015
- Founded
- 1922
- Industries
- Automotive, Medical Technology, Packaging, Electronics, Nonwoven & Hygiene, Food
- 01
Application consulting and feasibility testing
- 02
Tool design with 3D FEA
- 03
CNC manufacturing of horns (sonotrodes) and tools
- 04
System assembly and integration
- 05
Application testing (tensile testing, microtome, 3D surface scan)
- 06
Service, repair and training
Materials and Processes
Thermoplastic resins (rigid and flexible)
Base materials for all plastic welding processes from ultrasonic to hot plate.
Polycarbonate
Glass-like thermoplastic material for transparent welded joints.
Copper
Material for ultrasonic metal welded joints such as wire-to-busbar in EV batteries.
Aluminum
For busbar connections and copper-aluminum mixed joints with low heat input.
Titanium
Horn material for ultrasonic cutting knives, among other uses in food processing.
Locations
St. Charles, IL
USGlobal headquarters, manufacturing (CNC machine shop) and sales
- Materials
- Aluminum, titanium
- CNC Machine Shop
- Servo Ultrasonic Welding Systems Infinity™ / iQ Servo
- Application Laboratories
Kimberly, WI
USCenter of Excellence – Hygiene, Nonwoven & Packaging (bonding, sealing, cutting, labs, training)
- Materials
- Plastics, nonwovens
- Ultrasonic bonding systems
- automation-ready systems
- Test laboratories
Buford, GA
USFabric & Film Technical Center (feasibility, system design, tooling, training)
- Materials
- Films, textiles
- Ultrasonic rotary machines
- Film and Fabric Laboratory
Wixom, MI
USAutomotive Technical Center
Santa Catarina, Querétaro
MXDukane Mexico
Prague
CZCentral European Technical Center (Technical Applications and Service Center)
Parts and Applications
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Servo Ultrasonic WeldingJoining | – | – | – | – | Thermoplastic resins, Polycarbonate, glass-filled plastics |
| Vibration WeldingJoining | – | – | – | – | Thermoplastic resins |
| Laser Plastic WeldingJoining | – | – | – | – | Thermoplastic resins |
| Infrared Welding (contactless)Joining | – | 200 mm × 250 mm | – | – | Thermoplastic resins |
| Spin WeldingJoining | – | – | – | – | Thermoplastic resins |
| Hot Plate WeldingJoining | – | – | – | – | Thermoplastic resins (rigid and flexible), Thermoplastics |
| Ultrasonic Metal WeldingJoining | – | – | – | – | Copper, Aluminum, Copper-aluminum joints (dissimilar metals), Wire with 50 mm² to 95 mm² cross-section |
| Ultrasonic CuttingJoining | – | – | – | – | Thermoplastics, Textiles, Nonwovens, Food |
| Ultrasonic Sealing (film, sheet, packaging)Joining | – | – | – | – | biodegradable materials, paper-based packaging, films |
| Tool design and prototyping (3D FEA, sample tools, small series)Engineering | – | – | – | – | – |
| Application testing (tensile tests, microtome tests, 3D surface scanning)Testing | – | – | – | – | – |
13 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Servo ultrasonic welding system (Infinity™ with Melt-Match®, iQ Servo) | Dukane Infinity™ / iQ Servo | – | – | – | St. Charles, IL |
| Vibration welding machine (6000 series) | Dukane 6000 series | – | – | – | – |
| Laser plastic welding platform | Dukane | – | – | – | – |
| Rotary infrared welding machine (working area 200 x 250 mm, cycle time down to 8 seconds) | Dukane | – | 200 mm x 250 mm | – | – |
| Spin welder (all-electric servo press) | Dukane Servo Weld™ Plus | – | – | – | – |
| Hot plate welding machine (Thermal Hybrid Welder) | Dukane Thermal Hybrid | – | – | – | – |
| Ultrasonic metal welding module (servo-controlled, dual horn) | Dukane SynQro™ Quadro | – | – | – | – |
| Rotary Ultrasonic Metal Welding Module | Dukane | – | – | – | – |
| Rotary Ultrasonic Sealing System | Dukane Soniseal™ WD Series | – | – | – | – |
| Rotary Ultrasonic Sealing System | Dukane Soniseal™ 40 UL series | – | – | – | – |
| Ultrasonic generator (automation-ready) | Dukane iQ AiM™ | – | – | – | – |
| Rigid Acoustical Module (ultrasonic module for VFFS machines) | Dukane iQ RAM | – | – | – | – |
| CNC Machine Shop (machine building/tool fabrication) | Dukane | – | – | – | St. Charles, IL |
Additional services
Reference customers
Quality
Dukane is certified to ISO 9001 (certificate 202201 01.21.10, valid until 04.04.2027). The application laboratories provide tensile test stands, microtome testing and 3D surface scanning for testing welded samples.
| Evidence | St. Charles, IL |
|---|---|
| ISO 9001:2015 |
History
- 1922
Founded as Operadio by J. Mc William Stone, Sr.
- 1933
Appearance at the Chicago World's Fair; built a talking robot for Sears Roebuck.
- 1938
Sold over 1 million units of the Micromatic II.
- 1940–1945
Production of military and naval equipment (including paging systems) for World War II.
- 1950
Installation of a sound system at Comiskey Park, Chicago.
- 1951
Renaming of Operadio to Dukane.
- 1955
Founding of the Dukane Game Division.
- 1961
Opening of the Ionavac® Division (Ionovac HiFi loudspeakers).
- 1969
Development of an underwater locator device for flight data recorders in collaboration with NASA/FAA.
- 1970
Development of the first ultrasonic system, founding of the Dukane Ultrasonics Division.
- 1972–1981
Several patented ultrasonic technologies (transducers, horns, metal welding, among others).
- 1985
Invention of weld-by-distance technology in a project with Kodak.
- 1989
Start of global expansion with Dukane Canada.
- 1996
Receipt of ISO 9001 certification.
- 2001
Jack Stone, son of the founder, celebrates 50 years at Dukane.
- 2003
Opening of the Technical Applications and Service Centers in Prague and Shanghai.
- 2006
Opening of a Technical Applications and Service Center in Lyon, France.
- 2008
Launch of the iQ Servo, the first servo-controlled ultrasonic welding system, and patent application for Melt-Match®.