Ultrasonic welding had been widely used in various manufacturing industries such as aviation, medical, electronic device and many more. It offers a continued safe operation, faster and also low cost as it able to join weld part less than one second and also simple to maintain the tooling devices. Though ultrasonic welding brings a lot of advantages in assembly especially in thermoplastic material of manufacturing product, it also has a dominant problem to be deal with. The problem in ultrasonic welding is poor weld quality due to improper selection of ultrasonic welding parameters especially in near field configuration. Thus, an optimal combination of parameters is crucial in order to produce good quality weld assembly for this configuration. In this paper, ultrasonic welding process, ultrasonic weld joint defects and determination of optimal parameters for thermoplastic material had been discussed thoroughly.

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