SonoWeld 1600 Digital metal Spot WelderSonobond’s ultrasonic metal welders are keeping pace with the growing demand for advanced batteries and super capacitors. Two of our models are especially suited to helping manufacturers make the assembly process quick, reliable, and cost effective. Our SonoWeld® 1600 Digital Metal Spot Welder is ideal for welding multiple layers and/or delicate foils to tabs or terminals, as well as for assembling pouch cells. Another Sonobond model, the Dual Head Metal Spot Welder, has proven its capacity to weld up to 80 layers of foil to tabs and terminals in just one pulse. In fact, it is the only ultrasonic metal spot welder with this capability.

Broad Market for Batteries 

Lithium-ion and NiMH rechargeable batteries have a wide variety of applications. These include consumer products such as laptops, cordless and cell phones, video game controls, and toys. They are also used for electric cars (all-electric and hybrid), industrial  emergency lighting, power tools, and other essential technology. The production of these batteries often requires that multiple layers and/or delicate foils be welded to tabs or terminals. Sonobond’s ultrasonic technology enables this to be done quickly, costeffectively, and in an environmentally-friendly way. 

Multiple foil layers welded to tabThe SonoWeld® 1600 can weld up to 20 layers of foil, while the Dual Head Spot Welder confidently accommodates as many as 80 layers without tearing the delicate foils. In both cases, the weld is accomplished in a single operation that takes only seconds. Durable bonds are created without using heat, current, fluxes, or fillers. So there are no arcs, sparks or fumes produced, and there is no melting of the weldment.

The power supplies for these two models have a built-in microprocessor that permits storage and recall of over 250 weld protocols and features automatic frequency control and overload protection. A digital display allows selection of weld parameters by time, energy, or distance.

Both machines have heat-treated tool steel Taper Lock Tips that can perform up to 100,000 welds. These are designed for fast, convenient removal and replacement. In addition, the two models—like all Sonobond equipment—can be operated easily with only minimal training.

Sonobond’s Wedge-Reed System Offers Big Advantages 

All of Sonobond’s metal spot welders—including the SonoWeld® 1600 and the Dual Head—are made in the U.S.A. and feature the unique, patented Wedge-Reed bonding system of high vibratory force and low amplitude coupling. Shear mode vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded. This creates true metallurgical bonds that are precise and dependable. There is no bending stress or stalling. 

This is the only ultrasonic system with the capability of one-pulse welding of most oxidized and tinned metals without pre-cleaning.

Free Ultrasonic Welding Viability Test 

I encourage companies to take advantage of Sonobond’s free Ultrasonic Welding Viability Test. This is an easy way to determine if our machines are right for you. We’ll provide sample welds of your nonferrous metal application at no cost or obligation. Once you’ve seen that our Sonobond equipment provides the quality welds you need and you decide to make a purchase, we’ll work with you to ensure that the installation is as seamless as possible. I’m confident you’ll be impressed by our commitment to excellent customer service and solid technical support before, during, and after our equipment is installed.

Over 60 Years of Leadership 

Sonobond is a respected worldwide leader in the application of ultrasonic welding and bonding technology. It was in 1960 that the company—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding. Over the intervening 51 years, Sonobond has established and maintained a well-earned reputation for its pioneering work and quality-engineered products. Its many customers include leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, and ballistics industries. 

Additional Information 

To learn more about Sonobond products or the free, no obligation Ultrasonic Welding Viability Test, visit the company’s website at or call 800-323-1269. For immediate service, contact President Janet Devine at This email address is being protected from spambots. You need JavaScript enabled to view it..