Ultrasonic Spot Welders
the industry’s latest innovations for welding conductive metals.
Available in 15, 20 and 40 kHz, these ultrasonic spot welding systems deliver unique advantages due to the patented nodal mounting system. The quickest tool changes in the industry and unsurpassed reliability have made this product line an industry favorite. Sonics offers a wide range of configurations, each optimized for R&D, manual operation, specialized machines, or full automation. Standard versions are available for foil welding and wire processing.

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.

15 kHz Series

15 kHz ultrasonic spot welding systems are designed for larger applications requiring weld areas of hundreds of square millimeters. Systems are available in a wide range of configurations. Shown below are models for manual operation or R&D, for specialized machinery, and for automation. Ultrasonic stack assembly is also available.
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A complete 15 kHz system is comprised of an actuator and a power supply best suited to your application(s). 

20 kHz Series

20 kHz ultrasonic spot welding systems are designed to handle a wide range of ultrasonic metal welding applications, such as battery tabs, cable terminations, motors and coils; electrical connections; heat sinks; copper, aluminum, brass, gold and silver welding. Systems are available in a wide range of configurations. Shown below are models for manual operation or R&D, for specialized machinery, and for automation. Ultrasonic stack assembly is also available.
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A complete 20 kHz system is comprised of an actuator and a power supply best suited to your application(s).

40 kHz Series

40 kHz ultrasonic spot welding systems are designed for smaller and/or sensitive assemblies. 40 kHz ultrasonic metal welding systems are available in a wide range of configurations. Shown below are models for manual operation or R&D, for specialized machinery, and for automation. Ultrasonic stack assembly is also available.
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A complete 40 kHz system is comprised of an actuator and a power supply best suited to your application(s).

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