Ultrasonic Welding

Our equipment uses vibration and pressure to securely bond one or more wires in any direction with no extra material.

Our equipment uses vibration and pressure to securely bond one or more wires in any direction with no extra material.

Ultrasonic wire welding is a precise, high-speed process that uses ultrasonic vibrations to bond wires without heat or solder, ensuring strong, durable connections. Ideal for industrial, automotive, electronics, and aerospace applications, this method enhances reliability and efficiency. Our expert team offers tailored ultrasonic wire welding solutions to meet your specific needs, ensuring top-quality results for your projects

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What size wires can be welded together?

The ability to weld Copper and Aluminum wires is based on the physical size of the completed weld. As long as the weld is no larger than 1/4" x 1/4" we will be able to process the job.

 

Can different gauge wires be welded together?

Yes, as long as the combination of wires is less than 1/4" x 1/4."

The ability to weld Copper and Aluminum wires is based on the physical size of the completed weld.  As long as the weld is no larger than 1/4" x 1/4" we will be able to process the job.

 

What weld orientations can be processed?

Single Wire Butt Weld:

butt splice

This type of weld joins the end of a single conductor, functioning similarly to a ferrule but without adding extra material or increasing the thickness.

 

Multi-Wire Butt Weld:

multi weld

 

Designed for multiple wires aligned in the same direction, this weld can be used for a single connection or arranged in a series to create a "daisy chain."

 

Multi-Wire Splice Weld:

multi splice          multi splice 2

 

This weld fuses multiple wires in various orientations, such as end-to-end, end-to-middle, or middle-to-middle. It requires a minimum strip length of 5/8" and produces a weld with a 1/2" length

 

What do you need for a quote?

There are two standard ways to request a quote.

 

  1. Submit a template with wire(s) type, gauge, color, weld type/orientation, strip length, and wire length.
  2. Upload your drawings and we will include legend plates in our Ready to Assemble quote.

 

 

 

Request a Quote