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Ultrasonic welding · Components

Generators, converters,
boosters and sonotrodes.

The stack on its own — to retrofit a machine, replace a worn horn, or build ultrasonics into your own automation.

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You do not always need a machine. If you have a working press and the problem is a worn sonotrode, a failed converter or a generator that cannot be serviced, the stack is available on its own.

The four parts

Generator500 W – 5 kW20, 35 or 36 kHz. Modular — power can be upgraded without replacing the unit. Constant-amplitude control, amplitude selectable at 70/80/90/100%, live process display and data export.
ConverterPiezo stackTurns the generator output into mechanical vibration. The most common wear item after the sonotrode.
BoosterAmplitude scalingSteps the amplitude up or down between converter and horn. Changing the booster is often the cheapest fix for a weld that is under- or over-driven.
SonotrodeMade for your partThe horn that contacts the part. Designed and tuned to the geometry — this is the part that is never off the shelf.

About sonotrodes

A sonotrode is a tuned resonant body. Its length is set by the frequency, its face is set by your part, and its material is set by the duty:

  • Titanium — the best acoustic properties and the most durable. Used for high-amplitude, high-duty and abrasive-filled materials. The expensive option, and usually the right one.
  • Aluminium — excellent acoustically, lighter and cheaper, but wears. Common for large horns and for prototyping. Often hard-coated to extend life.
  • Hardened steel — used for insertion and staking where wear resistance matters more than acoustic efficiency, and for metal welding tooling.
Sonotrodes are consumables with a long life, not permanent tooling. They crack, they wear, and abrasive fillers — calcium carbonate, talc, glass — accelerate both. A horn developing an internal crack draws more power before it fails audibly; if your power draw is creeping up, have the horn scanned before it takes the converter with it.

Retrofits and rebuilds

Common jobs we are asked for:

  • Replacing an obsolete generator on a serviceable press
  • A second sonotrode for a new part on an existing machine
  • Changing the booster to fix a weld that is marking or under-welding
  • Building an ultrasonic head into a customer’s own automation or fixture
  • Spare converter and horn to hold as production insurance

Tell us what you have — make, model, frequency and power, plus a photo of the nameplate and the stack — and we will tell you what fits.

What are you welding?

Ultrasonic welding is decided by the parts — the resin, the wall, the joint and what the weld has to do. Send photos and drawings through the enquiry form and you get an engineered answer.

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