RF Welding Services
Contract RF welding & dielectric sealing for PVC, TPU, and urethane — military, medical, aerospace, and industrial applications
Overview
APPF Inc. is an experienced contract RF welding manufacturer serving military, medical, aerospace, and industrial customers from our facility in Westminster, CA. Using state-of-the-art Forsstrom RF welding machines and computer-driven ZUND cutting equipment, we produce airtight, watertight seals in PVC, TPU, and urethane materials — from prototype through high-volume production.
Radio Frequency (RF) welding — also called dielectric welding or high-frequency (HF) welding — uses electromagnetic energy at 27.12 MHz to excite polar molecules within thermoplastic materials. The resulting dielectric heating fuses the materials at the molecular level under controlled pressure and time, creating bonds that are often stronger than the base material itself.
Our facility features dual-head RF sealers, precision custom die tooling, and ZUND computer-driven cutting. We work closely with clients from initial prototype through full production runs, and our ITAR registration, Berry Amendment compliance, and CAGE Code (1NLJ3) make us a qualified partner for government and defense programs.
How RF Welding Works
RF welding operates at 27.12 MHz — the FCC-allocated industrial frequency for dielectric heating. When an RF field is applied across polar thermoplastic materials (PVC, TPU, urethane), the polar molecules within the material oscillate rapidly, generating heat from within the material itself. Combined with controlled pressure and cooling time, this produces a molecular-level fusion bond that is often stronger than the surrounding base material.
Unlike hot air or hot wedge welding — which apply external heat to the surface — RF welding heats the entire weld area simultaneously and uniformly. This makes it the preferred method for airtight seals, complex die-cut shapes, medical devices, and inflatable structures where seam integrity and dimensional precision are critical.
Step 1 — Apply RF Field
Electromagnetic energy at 27.12 MHz is applied across the material stack between tooling dies.
Step 2 — Dielectric Heating
Polar molecules oscillate, generating heat uniformly throughout the weld zone under controlled pressure.
Step 3 — Cool & Bond
Pressure is maintained during cooling, locking the molecular bond and producing a seam stronger than the base material.
RF Welding Materials & Applications
Weldable Materials
- • PVC — sheets, films, coated fabrics, vinyl
- • TPU — thermoplastic polyurethane films and coatings
- • Urethane — cast and film urethane materials
- • Coated fabrics — PVC-coated polyester, urethane-coated nylon
- • Multi-layer laminates — complex assemblies with polar outer layers
Industries Served
- • Military & Defense — inflatable structures, vehicle covers, fluid containment
- • Medical — catheter bags, surgical positioning, drainage bags
- • Aerospace — landing bag assemblies, inflatable aerospace components
- • Industrial — fluid containment, custom inflatable products
- • Consumer — inflatable products, promotional items
RF Welding vs. Other Joining Methods
| Method | Bond Type | Best For | Limitations |
|---|---|---|---|
| RF / Dielectric Welding | Molecular fusion | Airtight seals, complex shapes, medical, inflatable | Polar thermoplastics only |
| Hot Air Welding | Surface heat fusion | Tarpaulins, banners, large flat seams | Less precise, surface-only heat |
| Industrial Sewing | Mechanical stitch | Non-thermoplastics, structural seams, flexible assemblies | Not airtight/watertight without seam tape |
| Adhesive Bonding | Chemical adhesion | Dissimilar materials, field repairs | Lower strength, cure time, temperature sensitivity |
Frequently Asked Questions — RF Welding
Project Gallery
Capabilities
- PVC welding services — sheets, films, coated fabrics
- TPU (thermoplastic urethane) RF welding
- Urethane bonding and dielectric sealing
- Airtight inflatable structure fabrication
- Fluid containment systems
- Medical device RF welding (FDA Class 1)
- Military & defense RF welding (ITAR registered)
- Custom die tooling for complex geometries
- Prototype to high-volume production runs
- Computer-driven ZUND precision cutting
- Complex multi-layer assemblies
- Berry Amendment compliant manufacturing
Related Services
Need RF welding services? APPF Inc. — Westminster, CA · ITAR Registered · Berry Amendment Compliant