Sonobond Ultrasonics Metal Welding Technology

50 Years of Innovation and Leadership

For spot and multi wire-to-terminal welds, and delicate multi-layer foil-to-tab welds for lithium-ion batteries. Stores 250 protocols.

Welds wire bundles even if oxidized or tinned, creating a true metallurgical bond with the lowest possible voltage drop.

Suitable for integration into production line systems for PV cell manufacturing. Produces interconnects with excellent conductivity.

Welds wire bundles with cross-sectional areas up to 100 sq. mm.

Welds aluminum sheets up to 3mm thick and up to 80 layers of foil for batteries and capacitors.


Multi-wire to terminal weld Copper tube weld Multiple foil layers to tab weld Wedge-Reed System provides a high energy transfer for a superior weld


Sonobond's spot welders use the Wedge-Reed System for superior welds

The first patent ever issued for ultrasonic metal welding was awarded to Sonobond Ultrasonics (then known as Aeroprojects) in 1960. Since then, the company has been the worldwide leader in the development of ultrasonic metal welding equipment.

Sonobond ultrasonic metal welders create precise, solid-state metallurgical bonds without heat, current, or consumables. This is accomplished by introducing high-frequency vibration while the weldment is under moderately high clamping force. In this way, non-ferrous similar and dissimilar metals can be welded with repeated accuracy.

cover of Ultrasonics Metal Welding PrimerClick here to download Sonobond's free Ultrasonic Metal Welding Primer. It contains an in-depth explanation of the process and principles involved in ultrasonic metal welding, as well as helpful information about equipment and applications.

Sonobond's Unique "Wedge-Reed" Bonding System

Sonobond's metal spot welders have an important advantage over other types of ultrasonic metal welding equipment because they use the unique, patented "Wedge-Reed" bonding system.

This system maximizes metal welding effectiveness by combining high vibratory force with low amplitude coupling. Dependability is assured by utilizing shear mode vibration that is parallel to the welding surface. Bending stress is eliminated by positioning the line of force directly over the welding surface.

This bonding method permits the joining of thin-to-thin or thin-to-thick materials, including dissimilar metal joints. It produces joints with good thermal and electrical conductivity, while welding through most oxides and tinned metals. No special cleaning process is required.

A Wide Variety of Important Applications

Sonobond's ultrasonic metal welders are used to weld stranded wire-to-wire and wire-to-terminal for applications such as electrical wire harnesses and bus bars.

They are used to weld the terminals of lithium-ion batteries, foil-wound capacitors, thin aluminum or copper foil, and electrical contacts. They play an important part in the manufacture of fuses/circuit breakers, ignition modules, starter motors, and photovoltaic panels. And Sonobond's ultrasonic metal welders are also frequently used to close HVAC tubing, replacing crimp and solder methods.

Cover of Ultrasonics for Metal brochureClick here to download our free "Ultrasonics for Metals" brochure, containing an overview of Sonobond's ultrasonic metal welding expertise, equipment, and capabilities.

View the metal welding demo video


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