All products from Sonobond​.

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.

SonoWeld® 1600
Ultrasonic Metal Spot Welder

Ultrasonic Single Point Ground Welder SPG 2600

SonoWeld® 1600:

  • Performs spot welds, as well as wire-to-terminal welding
  • Welds multiple layers and/or delicate foils to tabs or terminals for lithium-ion and NiMH battery assembly
  • Joins up to 10 stranded wires from flat flexible circuit to multi-connection terminals in a single pulse
  • Microprocessor-controlled system allows storage and recall of over 250 weld protocols
  • Digital display allows selection of welding modes by time, energy or distance, with automatic frequency control and overload protection*
  • Outputs 1,500 or 2,500 watts of power to weld non-ferrous similar or dissimilar metal assemblies, including copper to aluminum
Ultrasonic Single Point Ground Welder SPG 2600:

  • Single point ground terminals used in complex automotive electronic components and circuitry
  • Ultrasonically welds up to 18 wires to a singleterminal with one pulse
  • Automatically folds the terminal arms to provide stress relief on the joint
  • Ultrasonically welds wire bundles of up to 20 square millimeters to a single terminal
  • Easy to-use, microprocessor-controlled unit accomplishes the weld in one pulse
  • Designed specifically for producing the single point ground terminals used in eliminating the electrical noise caused by the large number of complex electronic components in automotive circuits
  • Once the weld has been made, the unit automatically crimps the terminal arms around the wires to provide stress relief on the joint
  • Utilizes the patented Wedge-Reed system
    • Precise, ultra-reliable, solid-state metallurgical bonds without heat, current, fluxes, or fillers
  • Even lightly tinned or oxidized wires can be accommodated by the unit
  • Outputs 2,500 watts of power
    • Confidently handle up to 18 wires
  • Features a built-in microprocessor that stores and recalls up to 250 weld protocols and permits weld parameters to be selected by time or energy
  • Heat-treated, tool steel Taper Lock Tips perform up to 100,000 welds and can be easily removed and replaced.
  • Requires only minimal training

SpliceRite™ Ultrasonic Wire Splicer

Dual Head Ultrasonic Metal Spot Welder

SpliceRite™ Ultrasonic Wire Splicer​:

  • Creates a true solid state metallurgical bond with the lowest possible voltage drop, and minimal energy consumption
  • Produces no arcs, sparks or fumes, and does not melt the wires
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • Bonds wire bundles even if the wires are oxidized
  • 1500 and 2500 watt power supplies are available
Dual Head Ultrasonic Metal Spot Welder:

  • Features two ultrasonic welding heads, one on either side of the welding area, for increased welding capacity
  • Welds non-ferrous sheet metal, including aluminum up to 3mm thick, and reduces tip sticking on thinner aluminum as used for automotive applications
  • Welds up to 80 layers of foil to tabs and terminals, as used for advanced battery and super capacitor applications
  • Attaches wires to terminals
  • Accommodates lightly tinned or oxidized wires
  • Creates a solid-state metallurgical bond with high conductivity and without producing arcs, sparks or fumes, or melting at the weldment.
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • Uses Sonobond's 3,500 watt power supply

Dual Head SpliceRite™ Ultrasonic Wire Splicer

WeldMaster™ C-Frame I & II Ultrasonic Metal Spot Welders

Dual Head SpliceRite™ Ultrasonic Wire Splicer:
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  • Features two ultrasonic welding heads, one on either side of the welding area, for increased welding capacity
  • Welds wire bundles with cross-sectional areas of up to 100 sq. mm.—in a single pulse. It’s suitable for heavy-duty cables used in cars, trucks and industrial machinery
  • Accommodates lightly tinned or oxidized wires
  • Creates solid-state metallurgical bonds with high conductivity and without producing arcs, sparks or fumes, or melting at the weldment
  • Microprocessor controller welds by height, energy or time, and can recall up to 250 weld protocols
  • Uses Sonobond's 3,500 watt power supply
WeldMaster™ C-Frame I & II Ultrasonic Metal Spot Welders:

  • ​​​Effectively accommodates large metal parts, such as those used in the automotive industry
  • Outputs 2500 watts of power to weld nonferrous and dissimilar metal assemblies, including copper to aluminum
  • Virtually eliminates the problem of tips sticking to aluminum parts
  • C-Frame I has a 14-inch throat depth and a single head which usually completes the weld operation in less than 1.5 seconds
  • C-Frame II has an 18-inch throat depth and is available with a single or a double head, which further reduces weld time and energy

Tube Terminator™ Ultrasonic Copper & Aluminum Tube Welding

Foil Splicer™ Ultrasonic Foil Splicing

Tube Terminator™ Ultrasonic Copper & Aluminum Tube Welding:
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  • Hand-guided one-step crimp/seal copper and aluminum tube welder
  • Seals refrigerator/air conditioner tubing -- even when charged
  • Produces quick, airtight bonds without brazing
Foil Splicer™ Ultrasonic Foil Splicing:

  • Continuous seam welding and splicing units used in virtually all U.S. foil mills
  • For thin aluminum and copper foils up to 0.004"(0.1mm) thick and up to 48" wide
  • Seams and splices are produced faster and cleaner than by any other method
  • Welds aluminum interconnects between photovoltaic cells

Photovoltaic (PV) Ultrasonic Modular System

Photovoltaic (PV) Ultrasonic Modular System:
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  • Weld aluminum strips to metallized glass on PV modules
  • The resulting interconnects between the PV cells create an array with excellent conductivity
  • The high frequency (50kHz) low amplitude system precludes cracking of the glass panels
  • No melting, excessive heat, fluxes, filler metals, tapes or other consumables
  • Requires minimal training and is easy to operate and to integrate into PV handling systems
  • Power supply with automatic frequency control and welding head with a rotatable disk tip are suitable for integration into production line systems for PV cell manufacturing

Sonobond Ultrasonic Bonders Offer Unique Advantages for Nonwovens, Textiles and Filters.

SeamMaster® Ultrasonic Sewing Machine

SeamMaster® High Profile Ultrasonic Sewing Machine

SeamMaster® Ultrasonic Sewing Machine:

  • Versatile, general purpose machine works just like a traditional sewing machine
  • Cuts, "sews" and trims in one pass
  • Available in variety of stitch patterns
  • Applications: Medical disposables, filters, protective products, and thin film packaging
  • Operates without the use of thread, glue or other consumables
SeamMaster® High Profile Ultrasonic Sewing Machine:

  • Versatile, general purpose machine operates just like a traditional sewing machine
  • Features a large pattern wheel and high clearance above the bench for bulky materials and hand-guided operations
  • Virtually eliminates fraying or unraveling of bonded edges and seams
  • Requires minimal training to operate
  • Seals the outer shell of body armor. This enables the armor, with ballistic-resistant materials inside, to pass the current National Institute of Justice (NIJ) submersion tests. Per NIJ 0101.06, wet conditioning standards now require protection from submersion for 30 minutes rather than protection from a spray shower

SeamMaster® 10 Ultrasonic Sewing Machine

SeamMaster® Ultrasonic Modules for OEM's

SeamMaster® 10 Ultrasonic Sewing Machine:

  • Designed for table mounting
  • Ideal for patterns up to 10mm wide
  • Seams, cuts or trims synthetic fabrics and films without thread, adhesives or other consumables
  • 16” x 20” working area
  • Operates at up to 60 feet per minute
SeamMaster® Ultrasonic Modules for OEM's:

  • Provides OEM's with a cost-effective means to incorporate seaming, slitting, crosscutting, and trimming into special purpose machinery
  • Runs problem-free in continuous operation
  • Trims and seals in one pass, without thread, glue or other consumables
  • Single, multi-, or dual head arrangements
  • Available in a variety of easy-to-change stitch and slit pattern wheels

LaceMaster™ Ultrasonic Lacing, Quilting & Embossing Machine

SureCut™ Ultrasonic Cutters/Sealers

LaceMaster™ Ultrasonic Lacing, Quilting & Embossing Machine:

  • Over 500 roller patterns available
  • Embossing, quilting, and lacing
  • Patterned trims up to 2-7/8 inches wide
SureCut™ Ultrasonic Cutters/Sealers:

  • One-step cutting and sealing
  • Ideal for ribbons, trims, Velcro, and labels
  • Available in hand-held single cut or for loom-mounted operations

PlungeBonder™ Ultrasonic Textile/Filter Bonder

RingMaster™ Ultrasonically Attaches Collars to Filter Bags

PlungeBonder™ Ultrasonic Textile/Filter Bonder:

  • Easily bonds large pieces or hard-to-bond materials
  • Handles thick and multi-layer materials
  • Ideal for producing box-style filters and sealing ends of filter bags
  • Custom tooling enables straps made of coated synthetic material to be bonded within the seam of a ballistic vest's outer shell. This separate operation does not compromise the integrity of the ultrasonically sealed outer shell so the body armor continues to comply with current NIJ submersion requirements.
RingMaster™ Ultrasonically Attaches Collars to Filter Bags:

  • Attaches heavy-weight felted filter bags to rigid plastic collars
  • Strong, reliable bonds are completed in less than 10 seconds
  • Eliminates stitch holes that cause leaks, and thread that can get caught in pumps
  • Fast, easy re-tooling accommodates varying bag sizes and collar diameters
  • Produces up to 250 bags per hour

Ultrasonic Filter Collar Bonder™

Ultrasonic Cylinder Arm Machines

Ultrasonic Filter Collar Bonder™

  • Attaches nonwoven filter bags to plastic, circular collars
  • Creates a reliable 360° bond in as little as 45 seconds
  • Bonds without adhesives or stitching
  • Fast, easy re-tooling accommodates varying bag sizes and collar diameters
  • Easy to operate with only minimal training
  • Produces 50-80 bags per hour
Ultrasonic Cylinder Arm Machines:

  • Available in around-the-arm and off-the-arm models
  • Specialized functions for cuffs, sleeves, collars, pant legs, and filters
  • Optional arm extension for filtration applications

Hand-Held Ultrasonic Cutters/Bonders

Hand-Held Ultrasonic Cutters/Bonders:

  • Performs spot welds with exceptional control and accuracy
  • Ideal for cutting and bonding delicate plastic components, lightweight synthetics, nonwovens and plastic films
  • Eliminates the need for mechanical fasteners, adhesives and heat soldering
  • Can be configured for manual or production line applications
  • Automatic frequency control and overload protection

The Sonobond Family of Ultrasonic Plastic Bonders...

Widest selection of 20, 35, and 70 kHz units available anywhere!
Standard or microprocessor-controlled power supplies that can be attached or mounted separately!

Standard 3000/SureWeld™ 20 Ultrasonic Plastic Bonder

Easy 745/SureWeld™ 35 Ultrasonic Plastic Bonder

Standard 3000/SureWeld™ 20 Ultrasonic Plastic Bonder:

  • 1000 to 3000-watt power supply
  • For bonding large plastic parts or hard-to-weld materials
  • Especially useful in the automotive, appliance, packaging, toy, and housewares industries
Easy 745/SureWeld™ 35 Ultrasonic Plastic Bonder:

  • 400-, 600-, or 900-watt power supply
  • For welding smaller plastic assemblies or inserting metal fasteners
  • Applications include inserting screws into plastic, splicing film and scan-welding fabric, bonding micro-brush assemblies, and sealing air valve caps

Standard 50/SureWeld™ 70 Ultrasonic Plastic Bonder

Machine Builders Ultrasonic Modules for Plastic Bonding

Standard 50/SureWeld™ 70 Ultrasonic Plastic Bonder:

  • Most compact model on market
  • For welding micro-miniature or extra delicate components
  • Used by the electrical, packaging, and optical industries for welding plastic to plastic or plastic to synthetic fabrics and films
Machine Builders Ultrasonic Modules for Plastic Bonding:

  • Provide OEM's with a convenient way to integrate ultrasonic welding capability into special purpose machines
  • Fulfill the same functions as actuators, yet offer increased flexibility for automation projects in which space is at a premium
  • 20 kHz and 35 kHz models available
  • Easy changeover of the converter/booster/horn
  • Full 360-degree rotation of the acoustic stack

Hand-Held Systems for Ultrasonic Plastic Bonding & Cutting

Hand-Held Systems for Ultrasonic Plastic Bonding & Cutting:

  • Hand-held welding and cutting units allow for exceptional control and accuracy
  • Ideal for cutting and bonding delicate plastic components, lightweight synthetics, nonwovens and plastic films
  • High-frequency design (35 kHz & 70 kHz) prevents component cracking or breakage that can occur with lower frequency units
  • Eliminates the need for adhesives, mechanical fasteners, and heat soldering
  • Reduces labor costs associated with extra trimming steps
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