Sonobond in the News


Sonobond's team of technical experts is constantly improving and updating our product line to meet changing customer requirements.

For example, our SonoWeld® and our SpliceRite™ welders can process tin-coated wires and terminals-and they're the ONLY ultrasonic welders with this capability! Our equipment efficiently replaces soldering with a method that is faster and has better electrical conductivity.

Click on the SonoWeld® or SpliceRite™ pages, under Welders/Bonders section, for more information.

Ultrasonic bonding units from Sonobond Ultrasonics are providing AmericanAirFilter with a fast, efficient assembly method to manufacture several types of commercial air filters. AAF International®, located in Louisville, Kentucky, provides filtration products for HVAC applications, dust collection, nuclear and bio-chemical products.

Other joining methods may be cheaper to buy, but none is as cost-effective to use.

Ultrasonic welding is a proven method for assembling metal parts. Typical applications include wire harnesses, automotive parts, medical devices, rechargeable batteries, and copper tubing for heating, ventilating and cooling equipment.

Kuss Filtration Uses Ultrasonic SeamMaster from Sonobond in Assembly of Fuel Filters.

Ultrasonic metal welding holds distinct advantages over mechanical assembly devices and soldering, according to engineers at Electro-Canada, Toronto, (, a manufacturer of wire harnesses for automotive and off-highway industries.

When Polaris Pool Systems, manufacturer of automatic pool cleaners, needed a tighter seal for the bearing in its turbine wheel assembly, they utilized the SureWeld 20 ultrasonic plastic welder from Sonobond Ultrasonics. The welder, which is ideal for bonding large plastic parts, and hard-to-weld materials, ultrasonically welds the bearing into the turbine wheel, creating a strong molecular bond.

The Axiom Group, based in Ontario, Canada, manufactures wire harnesses and plastic components for automotive door mechanisms, but the company’s usual methods for crimping and soldering splices on wire harnesses weren’t up to par. “We used mechanical crimping,” says John Cresnik, general manager of the Axiom Group, “so different terminals were needed for the various wire combinations. This slowed production and increased costs.”

In 1988, the Sub-Zero Freezer Company of Madison, Wisconsin began utilizing a new ultrasonic welder from Sonobond Ultrasonics for its freezer and refrigerator assembly. Known as the Tube Terminator, this new welder had the capability to crimp and seal copper tubing quickly and cleanly without brazing. Sub-Zero was one of the first manufacturers to use ultrasonic technology for appliance assembly. At first, it represented a complete departure from their traditional assembly methods, but in the intervening 10 years, Sub-Zero has incorporated the Tube Terminator into a majority of its production lines, according to Dick Steinfeldt, Manufacturing Engineer at Sub-Zero. "The Tube Terminator is used to seal the copper tubes that charge the cabinet with refrigerant," says Steinfeldt. "With brazing, we had experienced a small amount of refrigerant leakage, due to bubbling in the crimp area during brazing. Since the ultrasonic Tube Terminator seals to one-wall thickness, we have eliminated any leakage problems."

“I wanted to challenge the students to increase their problem-solving abilities with an innovative [ultrasonic assembly] technology for fashion design.”

“I don’t have to worry about finishing my delicate jacket in the traditional way.”

“[My design] didn’t get bogged down by seam binding and heavy hems with this new [SeamMaster™ High Profile ultrasonic bonder].”

“I have so much more creativity than I realized just through using this new technology. I’m learning that I can stretch myself more but without abandoning my interest in graceful, elegant pieces.”

Anita Racine, Ph.D.,
Senior Lecturer and students
Apparel Design Program, Cornell University
Ithaca, New York

“The Sonobond unit replaced two industrial sewing machines. Those machines processed only about 20 feet of material per minute. But our Sonobond SeamMaster™ High Profile Ultrasonic Bonder runs approximately 30 or 40 feet per minute. That means our Sonobond bonder is definitely boosting efficiency, while reducing labor costs.

“Total maintenance fees for the sewing machines cost us about $2,000 a year. But thanks to Sonobond, we no longer have to worry about those fees or about losing valuable production time every week for routine maintenance.

“We got consistently good feedback about Sonobond from everyone we talked to. Sonobond personnel were also very responsive and a pleasure to deal with. I didn’t have to keep after them to get important information. Our experience has been so positive that I am keeping my eyes open for other applications where we may be able to use Sonobond ultrasonic bonding units in the future.”

Rob Perkins
Manager of Process Engineering
Velcon Filter
Sylacauga, Alabama

“We had been using a 20-year-old Sonobond machine and were very pleased. We knew there were other assembly methods. But, unlike ultrasonics, these other methods were less efficient and used consumables. We didn’t want that. When we contacted Sonobond to replace a manual we’d lost, they recognized that a new, customized unit could help us improve our existing processes.

“We’ve gotten outstanding results from our customized SonoWeld® 1600. We were also very pleased with Sonobond’s personalized service and fast turnaround. All of our questions were answered, the training was excellent, and the requested spare-parts quote was sent out immediately. It just doesn’t get much better than that.”

Chris McLaughlin, Maintenance Manager
Lake Cable, LLC
Valparaiso, Indiana