The PowerHouse of Ultrasonics
Application Finder Reset

Joining different material components by means of ultrasonic riveting. Simultaneous forming of two rivet heads.

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Reliable joining of metal with plastic through ultrasonic riveting with differential parts scanning.

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Low-vibration and secure joining of electronic components through ultrasonic riveting.

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Tight welding of injection-moulded parts without additional sealing elements with continuous process monitoring.

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Ultrasonic embedding of the metal SonicLok threaded bolt inserts into a plastic housing in a durable and low-tension manner.

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Simultaneous ultrasonic embedding of four threaded bushes into a POM cover flange so they cannot be extracted.

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Ultrasonic joining of a two-part injection-moulded dosing cap with a curved surface in a liquid-tight manner without markings.

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Reliable welding of the two-part outlet chamber in a liquid-tight manner. Joining other applications on the same installation without long retooling times.

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Liquid-tight joining of injection-moulded halves of an adapter, without loose particles if possible. The visible joining seam must not be visible through the transparent plastic.

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Tightly welding the two-part damper housing made of semi-crystalline POM. The joining zone is formed as a pinched-off seam. TCS5 process controller with convenient touch screen.

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Removing the filter rounds with ultrasonics and simultaneously sealing the edge zone without fraying. The housing is hermetically and permanently welded after inserting the rounds.

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High torsional strengths and stabilities can be achieved because of the ultrasonic embedding of metal thread inserts. All inserts are embedded in one process step.

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Securing insulation to a plastic cover at several points using ultrasonics. The process is carried out in a special plant with integrated IPA3505 actuator units.

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Despite the absence of a specific connection seam, an ideal connection is achieved by means of ultrasonic spot welding of two flat components.

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Protecting the opening in an electronic component against the ingress of dust with a fleece filter. Economical manufacturing of square filters with sealed edge zone and pointed corners with ultrasonics.

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Cutting out antiseptic dressings with additional functions from the base material with ultrasonics and sealing the edge zone against fraying at the same time.

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Softly sealing the edge zone of breathing masks with ultrasonics for high wear comfort. Additional insertion of high-strength strap openings.

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The production of face masks requires various separation and joining tasks which can be carried out perfectly with ultrasonics.

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Covering soft plastic foam rings for headphones with synthetic leather. All the required work processes should be carried out as far as possible in one setting.

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Compresses with various edge zones. Complete manufacturing of the compresses with ultrasonics in one process step. Removing the shapes and welding the edge zone at the same time.

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Securing electrical conductor tracks with zero backlash at several positions through ultrasonic riveting and individual path limitation.

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Joining injection-moulded plastic parts with a three-dimensional surface with stud welding.

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Ultrasonic far-field welding of the cylindrical, stepped plastic inlet with amorphous structure to the swirl chamber without sealing elements.

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Tight welding of a memory chip into a two-part polyamide housing with high amplitude requirement. Using a sonotrode made of high-strength titanium alloy.

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Tight welding of a panel with a curved surface onto a plastic housing with LEDs without damage with a carefully designed joining seam.

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Accurate ultrasonic welding of the two housing halves of an electronics coupler into the right position. Integrating the ultrasonic joining process into the automatic production line.

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Tight welding of a reflector made of PMMA onto a rectangular ABS/PC housing without markings. Monitoring the welding quality and recording the process parameters.

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Welding a large inspection window into the cover of an electricity meter without any markings and in a precisely parallel position.

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Welding a sensor with sensitive electronics into the housing. The electronics components are not damaged due to the correct joining seam design and the frequency selection.

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Cost-effectively securing the electronics circuit board to the connector assembly with ultrasonics without damage. Spring-loaded rivet unit for small-diameter rivet shafts.

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Hermetic welding of an end cap after filling the cartridge. Thanks to ultrasonics, no adhesives or solvents are required for joining.

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Tight and particle-free welding of a previously mechanically punched-out membrane into a medical plastic component without damage.

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Despite the absence of a specific joining seam, thin, flat and flexible knitted material can be reliably connected by ultrasonic spot welding without any problems.

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Precise and economical compacting of the end of electrical cable sets in various configurations. Quality control integrated in the production process.

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Economical and reliable manufacturing of strand node connections made of Cu/Cu, Al/Al or Al/Cu with the same quality. Quick conversion of the production installations with the same quality.

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Welding the strand end nodes for the board assembly wiring harness. Handling, accessibility, KSK compatibility and quality control are important prerequisites.

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Electrical welding with ultrasonics of a mixture of Cu and Al strands in various configurations with as little contact resistance as possible.

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Welding a flat cable onto the PCB layer of a ceramic component without damaging the ceramic and peeling off the PCB layer.

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Securely welding enamelled Cu wires together onto a Cu terminal without removing the enamel first. The enamel residues must not affect electrical conductivity.

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Contacting terminals for grounding connections with Cu strands. The individual cores must be firmly welded within the lateral contact limits.

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Electrically connecting terminals for battery contact with Al cables with a 35–42 mm2 cross-section in a reliable manner. Simple adaptation of the welding system to various cable sizes.

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Electrically connecting MAS terminals for high-current applications in vehicle construction with Cu cables in a reliable and conductive manner. Simple adaptation of the welding system to the different product variants.

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Reliably compacting the end of a high-flex cable with 35 mm2 cross-section. Welding further cross-sections as well as cable types as end or intermediate nodes.

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Ultrasonic welding of polyethylene strips for geocells to form a honeycomb structure.

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Removing medical dressings consisting of several layers for wound-healing applications and reliably sealing the edge against fraying in a single process step.

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Cutting breathing masks, filters, antiseptic dressings or labels with ultrasonics and welding the edge zone.

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Cutting blind textiles to the right width and length with ultrasonics and reliably sealing the edge zone at the same time.

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Continuously and intermittently separating woven labels along the width and the length with ultrasonics. Soft and sealed edges with high wear comfort.

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Clean, industrial cutting of sandwiches with ultrasonics at high speeds without squashing.

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Industrial cutting of cakes without squashing the product and without products sticking to the blade.

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Clean cutting of cakes and biscuits without products sticking to the blade. Industrial processing with high utilisation factor.

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Sealing the packaging bag reliably and tightly after filling, even if the welding area is contaminated.

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Sealing beverage packaging tightly through the liquid and welding in the pouring spout. Detecting leaking packaging by means of process data monitoring.

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Attaching a cardboard label header after filling and sealing tubular bags. The high production capacity requires short process times.

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Screening carbon powder with a wide grain size range without a throughput bottleneck forming on the upper sieve decks with small mesh sizes.

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Screening tungsten powder with small grain size distribution with fine mesh width and high throughput.  Ultrasonic technology increases the throughput and reduces the risk of clogging.

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Screening medical powder for tablets with optimal separation precision. Keeping the screen fabric free from clogging for a long period of time for the required grain size tolerance.

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Determining the grain size distribution of ground, classified pigment powders using ultrasonics-supported screening analysis.

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Visually perfect surfaces thanks to the precise fractionation of the powder and minimisation of the amount of incorrectly sized grains thanks to ultrasonic support in screening machines.

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Cutting fabric or other materials with ultrasonics and, if required, simultaneously welding the edge. Producing any shapes in x/y systems and with 3D robots.

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Economically removing even cut-outs for respiratory masks and sealing the edge zone for good wear comfort in one process step. 

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Welding a large number of battery current collector foils made of Cu to a Ni-coated Cu collector with minimum loss of power.

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MAK terminals are mainly used in vehicle construction for high-current applications. The welding system must adapt to different cable dimensions and terminal sizes.

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Eyelet terminals are used for attaching grounding connections to the motor vehicle chassis. The individual cores must be firmly welded within the lateral terminal limits. 

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Welding a very fine-cored, Cu high-flex cable with 50 mm2 cross-section to a Cu contact with a maximum welding width of 9.6 mm. The fine individual strands must not be damaged.

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Connecting a switch assembly made of fine-cored Cu strand with two contact parts (partially coated with Ag). The strand is pre-compacted at both ends.

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Connecting the contact pins of a stator with enamelled winding wires in a electrically conductive manner. Different numbers of wires and no previous removal of the enamel layer.

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Owing to the increases in the price for copper, aluminium is becoming more and more important. Ultrasonic welding technology is just as suitable for aluminium strands as it is for copper strands.

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Securely and quickly compacting a copper braid at the ends with ultrasonics.

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Welding punched Cu contact studs onto a delicate Cu punched strip during the manufacturing process. No damage to the contact tracks and minimal electrical contact resistance.

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Flush welding flat, rectangular copper conductors using ultrasonic technology without substantial thickening due to overlaps.

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Fractionating soldering powder in various qualities and large quantities with SONOSCREEN®easy in double-decker screening systems with excellent separation precision. 

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Screening fine makeup powder in large quantities, different colour shades and different qualities with high throughput rates and without any clogging of the screen.

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Aluminium oxide is processed in various industries. The screening system must fulfil strict requirements with regard to capacity, screen life and separation precision.

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Sugar is available in different qualities and grain sizes. A high throughput rate, fractionation and dedusting must be provided by means of a suitable process.

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Engines comprise many individual high-precision components. The parts must be cleaned in a reproducible manner before a subsequent process step.

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Reliably removing residual dirt from pistons and connecting rods for final engine assembly using ultrasonics. Controlled by ProfiNet bus systems

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High cleaning standards for surface-treated components such as exhaust systems. Fully automatic, reliable and reproducible cleaning with ultrasonic tube resonators.

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Removing oil, dirt, polishing paste or machining residues from small parts after final manufacture. Cavitation of ultrasonic tube resonators even reaches concealed places.

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Contacting an Al capacitor housing with a grounding connection solder tail. Limited access to the contact point inside the housing.

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