Ultrasonic welding is a widely used technique for joining thermoplastic materials due to its efficiency, speed, and reliability. In this study, we investigate the weldability of acrylonitrile butadiene styrene (ABS) material used in the manufacturing of volume control sockets for earphones through ultrasonic welding. The experiments were designed to explore the effects of weld time, hold time, and input energy on the quality of welds. Various non-destructive, radiographic, and microstructural analyses were performed on the weld samples to evaluate their integrity and mechanical properties. The weldability study was conducted using a systematic approach, varying the process parameters systematically to observe their impact on the weld characteristics. The weld samples were subjected to microstructural studies using SEM and XRD analysis to assess the morphology, inconsistencies, chemical changes, phase composition, crystallinity, and thermal stability after the welding process. The results obtained from these tests were analyzed to draw correlations between the process parameters and the weld characteristics. By comparing the weld quality with variations in weld time, hold time and input energy, we were able to identify optimal welding conditions that maximize the strength and integrity of the welds while minimizing defects and inconsistencies. The significance of these findings lies in their contribution to establishing the weldability of ABS material using ultrasonic welding for earphone volume control sockets. The comprehensive characterization of the welds provides valuable insights into the underlying mechanisms governing the welding process and informs the development of optimized welding procedures for industrial applications. This study contributes to the advancement of ultrasonic welding technology in the production of high-quality plastic components with enhanced performance and reliability.