"We switched from steel to plastics for the cooling hose MBQ due to weight and cost reasons.
Ultrasonic welding was the only technically feasible joining method. However, to join the hoses and the holders via ultrasonic vibrations was a hard piece of engineering, because of the multi-bend hoses. Not only the energy directors on the holders (where the ultrasonic energy is focused to initiate melting) had to be adapted, but also the fixtures had to be elaborated extensively. With the help of a thermal imaging camera and cross sections we were able to master the process and to determine the weld parameters. The result is an economical assembly process which we are proud of."