This section provides an overview for ultrasonic welders as well as their applications and principles. Also, please take a look at the list of 19 ultrasonic welder manufacturers and their company rankings. Here are the top-ranked ultrasonic welder companies as of November, 2023: 1.Forward Technology, 2.Sonitek Corporation, 3.Dukane Corp.
An Ultrasonic Welder is a mechanical device that uses the heat generated by friction between objects to weld them together.
It is mainly used for joining plastic materials and dissimilar metals.
Because welding is performed by frictional heat, it consumes less power than other heating-based welding methods. It offers easy automation and ensures high reproducibility, as well as a good appearance after welding because no adhesives are used.
Developed in the 1960s, Ultrasonic Welder has been in use for over 50 years. It typically consists of an oscillator and welding table or a transducer and horn. By applying simultaneous ultrasonic vibration and pressure, this device can quickly melt and bond resin and metal materials. Ultrasonic welding machines find extensive applications across various industries. Key features of this welding machine are that it does not use any adhesives, so the appearance after welding is beautiful, it is environmentally friendly because it uses instantaneous frictional heat to weld, so it consumes less power, and its easy to automate, so it is highly reproducible.
The main applications of Ultrasonic Welders are as follows:
Ultrasonic welding can be used to bond metals as well as plastics. Its also used to bond metal terminals and wiring, and metal wires inside IC chips.
Ultrasonic Welder is a device in which a transducer, called a horn, applies a certain amount of pressure between the materials to be bonded. The vibration of the horn transfers energy to the bonded surfaces for welding.
The frictional heat generated between the surfaces of the bonded objects makes welding possible. Especially when the object to be welded is metal, the ultrasonic vibration causes the metal surfaces to rub against each other, destroying the oxide film on the surfaces and providing bonding strength.
Ultrasonic Welders consist of an oscillator and a transducer. The oscillator is a device that generates ultrasonic vibrations and is designed to have a constant amplitude so that the amplitude does not change depending on the type of material to be welded. By keeping the amplitude constant, the quality of the product after welding can be ensured. The transducer consists of a Langevin transducer (commonly known as a BL transducer) and a horn member that transmits the vibration. Ultrasonic Welders perform welding by propagating ultrasonic waves from the horn to the welded product.
Ultrasonic Welders tend to melt the heated material if the welding time is too long, while the resin tends to carbonize if the welding time is too long. Also, the pressure generated when the object to be welded is held by the horn reduces the welding time if the pressure is high, but too much pressure can also cause the object to stop melting. The important point is to control the three factors, namely, time, pressure, and heat, and ensuring they remain within an appropriate condition range.
Advantages of Ultrasonic Welding include the following:
While the following points are some disadvantages:
An ultrasonic horn is a component that efficiently transfers vibration energy to the object to be welded. Ultrasonic waves are converted into mechanical vibration amplitude energy by a transducer, and then amplified by a transducer called a booster before being transmitted to the horn. The amplitude is gradually amplified and then optimized at the horn tip. By concentrating the ultrasonic vibration at the horn tip, the object is impacted 40,000 times per second (at 40 kHz).
Ultrasonic horns are available in the following types:
Ultrasonic horn materials are used according to the purpose of welding, and the following materials are mainly used:
Ultrasonic Welders are also used in mask manufacturing. Ultrasonic welding machines use ultrasonic vibrations to melt materials and weld them together to produce the twill lines and engravings on masks. This process eliminates the need for threads and adhesives, simplifying the production process.
In addition, the mask can be welded to the mask body with ear strings made of different materials such as natural latex rubber for the rubber part and PE for the thread parts. This ensures that the mask can be manufactured with a single equipment. It is expected that the use of Ultrasonic Welders in mask production will increase in the future.
*Including some distributors, etc.
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Interstate Plastics, established in 1980 and headquartered in Sacramento, California, USA, is a full-line distributor of plastic products. The company supplies a wide range of plastic sheet, rod, tube & bar, film, and profiles, along with accessories and care products. From laser cutting to various plastic materials, it caters to diverse industries such as semiconductor, medical, and aerospace. The company also offers full sheets, cut-to-size options, and CNC plastic manufacturing solutions. With a DMCA-protected product line and Level 2 verification, the company operates in over 10 locations across the nation, including Sacramento, Austin, and Boise.
SharperTek, based in Detroit, Michigan, and established in 1998, is a manufacturer and supplier of custom ultrasonic cleaning systems and parts degreasers. The ultrasonic cleaners include carburetor cleaning systems, automated parts washers, jewelry steam cleaners, and blind & stencil cleaners. The industrial cleaners include pressure washers, power lift with agitation, ultrasonic vapor degreasers, cabinet spray washers, and ultrasonic gun cleaners. These are used in nuclear, electronics, chemical, metals, ceramics, and honey processing industries. The products have an annum warranty and services such as parts cleaning, return & refunds, and finishing services.
Sonitek Corporation is a manufacturer and supplier of heat staking and ultrasonic welding systems and tooling that was established in 1989 and is headquartered in Milford, Connecticut. The company produces a wide range of heat staking and ultrasonic welding systems, including benchtop systems, automated systems, and custom systems. Its products, such as TS-100 Benchtop Heat Staking System, USW-2000 Automated Ultrasonic Welding System, and Custom Heat Staking and Ultrasonic Welding Systems, are used by a number of industries, such as electronics, medical, and automotive. The company also provides a range of services, including system integration, tooling design and fabrication, and training.
Dukane Corp, established in 1922, is a manufacturer of plastic joining, sealing, or cutting products such as ultrasonic products, spin welders, laser plastic welding systems, hot plate welders, and rotary ultrasonic solutions used in automotive, medical, ultrasonic cutting, food, and packaging industries. The company in St. Charles, IL, has ISO 9001 DQS and IQNet registration certificates and offers vibration welding, servo ultrasonic welding, laser welding, infrared welding, and particulate-free welding. The company has DukaneKVT as an affiliate.
Sonics & Materials Inc., founded in 1969 with headquarters in the USA, is a manufacturer of a broad range of plastic welding equipment, tooling, and components. The company's manufacturing is divided into four divisions: plastics assembly, liquid processing, metal welding, and ultrasonic cutting and sealing. Sonics & Materials Inc.'s products include ultrasonic plastic welders, vibration welders, hand-held units, bench model presses, and ultrasonic kits for OEM installation. The company holds ISO 9001 certification and also offers custom design, tooling, and production of equipment for client-specific requirements.
MS Ultraschall Technologie GmbH, founded in Spaichingen, Baden-Württemberg, in 1965 is a manufacturer of turnkey custom ultrasonic machines. The company's product portfolio includes ultrasonic series machines, ultrasonic series welding machines, ultrasonic systems, ultrasonic components and Workpiece holders and anvils. They serve markets such as the Packaging Industry and Food, Textile Industry, Medical Technology, Consumer Goods and Electrical components. The company also provides services including engineering support, after-sales services and distribution.
Nippon Avionics Co., Ltd is a Japanese manufacturer of electronic aviation equipment and other office equipment. The incorporation is a result of merging NEC Corporation and Hughes Aircraft Company in 1960. Headquarters are located in Yokohama Japan. The company designs, manufactures, and sells items from three product lines: Information Systems, Joining Equipment, and Infrared Thermography. The products include communication devices used in aviation integrated circuit (IC) boards and media projectors for office use.
Founded in 1890 in Missouri, Emerson Electric Co., is a technology and engineering company that provides various solutions for customers in industrial, commercial, and consumer markets globally. Business segments include automation solutions, AspenTech, and commercial & residential solutions segments. The Automation Solutions segment offers measurement and analytical instrumentation, industrial valves and equipment, and process control software and systems. The AspenTech segment provides asset optimization software for enhancing performance through a combination of modeling, simulation, and optimization capabilities. The Commercial & Residential Solutions segment offers residential and commercial HVAC products, system protector and flow control devices, and IoT thermostats.
Forward Technology, established in 2000, is a manufacturer of custom and standard plastic welding equipment and testing systems suitable for thermoplastic parts. The plastic welders are used for hot plate welding, spin welding, vibration welding, infrared welding, and leak & burst testing. The company also provides automated assembly systems and robotic integrations such as rotatory, incline, and pallet transfer systems for increased efficiency and quality in production. It is located in Cokato, Minnesota, and is a member of The Crest Group Company.
Sirius Electric S.r.l., founded in 1989 and based in Vigevano, Lombardy, is a manufacturer of welding machines for plastic materials. The company offers a range of products, including ultrasonic welders, vibration welders, spin welders, hot plate welders, and customized special machines. It also designs and produces sonotrodes, using high-level simulation software systems to verify future operations. In 2023, Sirius Electric joined SILMO in Paris for an eyewear trade show to showcase its welding technologies, including the special automatic vibration welder, the COMPACT ultrasonic welder, and the manual VSP vibration welder used in the production of acetate glasses.
SONIC ITALIA SRL, established in 1987 and based in Italy, is a manufacturer of thermoplastic welding and cutting solutions using ultrasonics. The company also produces products such as semi-automated welding systems, continuous welding systems, ultrasonic welding machines, ultrasonic portable welding kits, and ultrasonic converters. All the products made by the company are supplied to different application sectors such as fabrics, plastics, automotive, food, and packaging. The company designs and develops products after research and experimentation, and all products undergo laboratory tests to check for quality.
FRIMO has been a supplier of plastics processing systems out of Lotte, Germany, since 1968. The company creates customized products, including models, fixtures, tools, and automated solutions. It provides technologies such as PU processing, thermoforming, edge folding, flexible trimming, and press laminating for interior or exterior components and lightweight construction use in the automotive sector. The firm also offers post-purchase services like training, replacement components, maintenance, remodeling, and relocation. It has received 26 SPE awards, two JEC awards, and one AVK award.
MECASONIC was founded in 1969 and is headquartered in Juvigny, France is a manufacturer of ultrasonic welding apparatuses. The company offers a diverse product portfolio including metal welding devices, hot plate welding, and integrating components. It also provides services like testing laboratories, after-sale services, and training materials. These products have applications in the assembly of exterior vehicle lights, welding of FFP2 and surgical masks, and rivet printed circuits without damaging them.
Abbeon Cal Inc. is a supplier and distributor specializing in measurement and calibration solutions, established in the United States in 1946. Abbeon Cal Inc. has been a partner for industries requiring precision measurement tools. Abbeon provides a comprehensive range of products including calipers, micrometers, gauges, and thermometers. The company is a preferred choice for professionals in manufacturing, engineering, and research sectors. Abbeon Cal Inc. is able to provide tools that ensure accurate measurements and lead to improved efficiency.