- Home
- Ultrasonic wire welding
Ultrasonic wire welding
Automotive · Electronics
Ultrasonic welding enables the precise and reproducible joining of copper and aluminum conductors as well as various cable and terminal components. Through mechanical ultrasonic vibration, the parts to be joined are bonded together under a defined force without the need for solder or flux.
The process is suitable for various cable cross-sections, conductor materials, and connection geometries. Process parameters such as welding force, amplitude, and welding energy can be specifically adapted to the respective application.
Our ultrasonic cable welding systems are used, among other things, in the Automotive industry, electromobility, power electronics and cable assembly deployed.
Application Range
wire harness to terminal welding
wire-to-wire welding
FPC welding
Double-sided welding
Typical Materials
- Copper
- Aluminum
- Copper Alloys
- Aluminum Alloys
- tinned conductors
- Strand and braided conductors
Depending on the application, our systems are suitable for various conductor and contact materials.
The appropriate welding technology is selected based on the material, cross-section, component geometry, and desired joint quality.
Advantages of Ultrasonic Cable Welding
- Reproducible Electrical Connections
- Short processing times
- Low thermal stress on the workpieces
- No solder or flux required
- Suitable for copper and aluminum conductors
- Flexible processing of different conductor cross-sections
- Precise Control of Welding Force and Ultrasonic Energy
- Process Monitoring for Consistent Manufacturing Quality
- Suitable for automated production processes
Applications in Various Industries
Ultrasonic Wire Bonding
Automotive
Ultrasonic welding for wiring harnesses, electrical connections, terminals, and automotive electrical components.
Electric Mobility
Electric Mobility
Connectors for high-current applications, batteries, electric drive systems, and charging infrastructure.
Power Electronics
Power Electronics
Welding of copper and aluminum conductors, busbars, and electrical contact components.
Wire Assembly
Wire Assembly
Reproducible connections for various cable types, conductor cross-sections, and contact geometries.
Custom Cable Welding Solutions
Not every cable connection can be optimally implemented using a standard process. Therefore, the ultrasonic frequency, sonotrode, anvil, and process parameters can be tailored to the specific application.
We can assist you in selecting the right system, designing the process, and testing your cable and connector application.
Are you looking for the right solution for your cable connection?
Please contact us for a personalized consultation and feasibility study.
Relevant machines and technologies
