A solid-state bond in copper, aluminium and other non-ferrous metals — wire splices, terminals, battery tabs, busbars and tube seals, with no heat input and no current through the part.
Ultrasonic metal welding is a solid-state process. The metal never melts. Vibration under clamping force scrubs the oxide layer off both surfaces and brings the clean metal underneath into contact until the atoms bond — no heat input, no current through the parts, no filler.
Because there is no melting, you can join metals that resistance and laser welding handle badly — copper to aluminium, thick to thin, multiple strands to a solid terminal. The heat-affected zone is minimal, so components alongside the joint survive. And the process cuts through surface contamination rather than trapping it in a weld pool.
Joining multiple copper conductors into a single splice, typically in a wiring harness. Fast, no solder, no crimp, and the joint is smaller than the alternatives — which matters when it has to fit inside a loom and be taped over.
Bonding flexible stranded wire directly to a flat terminal or lug. Better conductivity than a crimp, and no risk of a cold solder joint.
The application driving the most growth. Joining thin foil tabs to cell terminals and connecting cells into modules with copper or aluminium busbars — without heating a cell that must not be heated. EV packs, energy storage, tool batteries.
Pinching and sealing copper and aluminium tube in a single operation — a hermetic, leak-tight seal used in refrigeration and HVAC in place of brazing.
| Type | What it does |
|---|---|
| Wire splicers | Compact splices from multiple conductors. Splice cross-section set by the tooling. |
| Spot welders | Discrete lap joints — tabs, busbars, foils, terminals. |
| Rotary / seam welders | Continuous seams in foil and thin sheet. |
| Sonotrodes & anvils | The wearing pair. Knurled faces grip the metal; both are consumable and are matched to the joint. |
Power and frequency are specified per application — splice cross-section, material combination and cycle rate drive the machine selection. Send the joint details through the enquiry form.
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, not a price range.