Ultrasonic Welding (USW) is a rapidly upcoming technology for joining high performance Thermoplastic Composite (TPC) structures in the automotive industry. With the focus shifting from metals to composites for primary structures, USW process is seen as a fast, clean and efficient alternative for the conventional joining methods. Continuous Ultrasonic Welding (CUW) is an innovative, upscaled version of the USW process, where the weld is made over a moving part to create a weld line instead of a single spot. Currently, there has been very limited research done in this field and the technology is in very early stages. The key to success of this technology lies in creating a uniform weld of an acceptable lap shear strength (LSS). Recent research has suggested that using a woven mesh as an energy director (ED) at the interface provides a good uniformity along the weld line, along with an acceptable LSS value. The research shows how the mesh deforms prior to the melting process, creating an intimate contact between the adherends and how this has a positive effect on the weld uniformity. This study uses this data to design and manufacture a new ED that has these beneficial features incorporated in it. The study also uses an expanded mesh as an ED to study the effect of open areas in the weld uniformity. The EDs are used in the CUW process and compared based on their different features. Through this study, a deeper understanding of the behaviour of EDs during a CUW process is established which will be useful for developing new means of optimizing this process.