Seam Welders
seamlessly engineered to perfection.
Sonics’ seam welding systems can accommodate a wide range of copper and aluminum foil applications. A wide range of configurations are available for applications such as web roll, heat exchangers, continuous foil sealing and gantry mounting.

Metal Welding

  • Ultrasonic Metal Welding is the ideal process for bonding conductive materials such as copper, aluminum, brass, gold and silver.
  • The process is environmentally green as no solders, flux or braze material are required.
  • The process is a cold weld so that components are not annealed and no harmful inter-metallics are formed during welding.
  • Weld tooling typically lasts for several hundred-thousand cycles with no maintenance.
  • Excellent welds are achieved with otherwise difficult applications, such as welding materials that are dissimilar in thickness and composition.
  • Very little energy is expended. A typical weld uses under 2000 watts and is completed in under one-half second.
  • The ultrasonic weld is extremely reliable with built-in process monitoring to help assure zero rejects.
  •  ​Large weld areas of up to 150 mm sq. can be produced with our 6000 watt power supply.

Patented nodal mounting system.
Patented 90° self-orienting keyed horns and tips.

Model MSW20

Model MSWA20 Vertical Actuator

Model MSW20A20ST12 Actuator with Motorized Slide Table and Plate​

Model MSWA20RA Actuator with Rotary Anvil and Plate
Rigid Dual Cross Roller Bearing Stack Housing
Steel Ultrasonic Rotary Horn
Weld Patterns Available in Various Widths and Knurl Patterns
Zero Contact and Frictionless Rotary Commutator
Single Piece, Dual Nodal Mount Horn and Booster Stack

Application Examples
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Welding the ends of foils to form a continuous web
Fabricating a continuous tubing from flat stock
Bonding copper and aluminum sheets to tubes to fabricate thermal solar systems
Bonding conductors to photovoltaic cells

SmartControl Power Supplies

Using the full color touchscreen, the operator can intuitively enter weld parameters with job storage and recall capabilities. Available in 1500, 2500 and 4000 watts peak power.
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  • Weld results viewable as numerical values and on time-based graphs
  • Data logging to an external PC for data storage for quality analysis
  • Barcode reading feature for parameter selection