This automated ultrasonic welding and leak-testing machine is specifically designed for cell culture flasks (comprising the flask body and cap or breathable filter membrane). It integrates two core
This automated ultrasonic welding and leak-testing machine is specifically designed for cell culture flasks (comprising the flask body and cap or breathable filter membrane). It integrates two core processes—welding and leak testing—into a single system that combines automatic feeding, ultrasonic welding, cooling/setting, in-line leak testing, and automatic sorting of good versus defective parts. This enables a fully automated, closed-loop workflow from loose components to finished products, effectively resolving long-standing issues associated with traditional adhesive bonding or hot-plate welding, such as low efficiency, inconsistent sealing, and reliance on manual spot-checks. It helps manufacturers of biopharmaceutical consumables upgrade their welding and leak-testing processes to achieve standardization, high efficiency, and reliability.
The equipment automatically feeds flask bodies and cap/membrane assemblies via vibratory bowls or hoppers. Using a precision rotary table or linear slide, it sequentially performs component positioning and assembly, ultrasonic welding, cooling and setting, airtightness testing, and sorting/unloading of qualified products—all without manual intervention. It integrates seamlessly with upstream injection molding and downstream packaging processes; a single operator can monitor multiple production lines simultaneously, significantly reducing staffing requirements and labor intensity.
Built with a high-rigidity cast frame and an imported ultrasonic generator system, the machine delivers constant amplitude output. Combined with precision pneumatic clamping mechanisms and contoured tooling, it achieves a welding position repeatability of ±0.05mm, ensuring consistent weld strength, flash-free finishes, and leak-proof integrity for every flask. The leak-testing unit employs a high-precision differential pressure sensor with a resolution of ±0.1Pa, effectively eliminating interference from ambient temperature fluctuations. Key sealing components and welding horns undergo wear-resistant treatment, enabling stable, continuous 24/7 operation. The combined defect rate for welding and leak testing is below 0.2%, guaranteeing highly consistent sealing performance across product batches.
Equipped with a PLC and industrial touchscreen, the system stores welding and leak-testing parameters (such as welding time, pressure, amplitude, cooling time, and test pressure/hold time) for hundreds of flask specifications (covering body dimensions, materials, and welding areas), allowing for rapid product changeovers with a single-button command. Equipped with real-time monitoring systems for welding power and pressure profiles, the machine automatically detects defects such as weak welds, over-welding, and seal failures, triggering an audiovisual alarm and automatically rejecting defective units. It also supports production data storage and MES integration, ensuring full traceability across the entire welding and leak-testing process.
The cycle time for welding and leak-testing a single unit is just 4–8 seconds (depending on bottle specifications and weld area), enabling a daily output of 12,000 to 18,000 units per machine—a 5- to 8-fold increase in overall efficiency compared to traditional manual welding combined with offline sampling-based leak testing. Its integrated design eliminates intermediate buffering and handling steps, significantly reducing the risk of microbial contamination from human contact and minimizing costs associated with quality-related rework, thereby lowering total operating costs by over 50%.
Centered on the seamless integration of precision ultrasonic welding and high-accuracy leak-testing technologies, this automated machine ensures that the seal quality of every culture bottle withstands the rigorous demands of both cell culture and transport/storage. Choose this solution to move beyond the inefficiencies and inconsistencies of fragmented welding and testing workflows, and ensure your culture bottles—consistently high in quality—are ready for the forefront of global life sciences and biopharmaceuticals.
Technical parameters:
Equipment Model: GST-PYP100A
Freezing tube capacity: 25-250ml
Sizes: L2550*W2000*H1500(mm)
Production Capacities: 600pcs/h
Power (Output): 1.5kw
Customized Support: Yes
