Over 60 Years of Innovation and Leadership

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Sonobond Ultrasonics (then known as Aeroprojects) invented ultrasonic metal welding in 1960. We received the first patent ever issued for this technology, awarded for our Wedge-Reed System. Since then, the company has continued to lead the industry with the development of innovative ultrasonic welding equipment for non-ferrous metals.

Sonobond’s ultrasonic metal welders create strong, precise, highly conductive solid-state bonds without heat, current, or consumables. Our Wedge-Reed System accomplishes this by introducing high-frequency vibration while the weldment is under moderately high clamping force. The System eliminates bending stress caused by other ultrasonic metal welders, achieves more durable welds than crimp or solder systems, and eliminates metallurgical defects found in fusion welds. It also uniquely joins metals that are oxidized or tinned – in just one pulse and without pre-cleaning. No other ultrasonic metal welder has this capability.

Click here to download Sonobond's free Ultrasonic Metal Welding Primer. It contains an in-depth explanation of the process and principles involved in ultrasonic metal welding, as well as helpful information about equipment and applications.

Sonobond's Unique "Wedge-Reed" Bonding System

Wedge-Reed SystemSonobond's metal spot welders have an important advantage over other types of ultrasonic metal welding equipment because they use the unique, patented "Wedge-Reed" bonding system.

This system maximizes metal welding effectiveness by combining low vibratory amplitude with high vibratory force. Dependability is assured by utilizing shear mode vibration that is parallel to the welding surface. Bending stress is eliminated by positioning the line of force directly over the welding surface.

This bonding method permits the joining of thin-to-thin or thin-to-thick materials, including dissimilar metal joints. It produces joints with good thermal and electrical conductivity, while welding through most oxides and tinned metals. No special cleaning process is required.

Download link for the Comparison of Ultrasonic Metal Welding SystemsClick here to download Sonobond's free Comparison of Ultrasonic Metal Welding Systems. This technical data sheet contains in-depth explanations of the two systems used for ultrasonic metal welding—Sonobond's patented Wedge-Reed System and our competitors' lateral drive system. A comparison of both systems' design and operation; their capabilities, amplitude and force differences; and the importance of matching system and load impedance are included.


A Wide Variety of Important Applications

Sonobond's ultrasonic metal welders are used to weld stranded wire-to-wire and wire-to-terminal for applications such as electrical wire harnesses and bus bars.

They are used to weld the terminals of lithium-ion batteries, foil-wound capacitors, thin aluminum or copper foil, and electrical contacts. They play an important part in the manufacture of fuses/circuit breakers, ignition modules, starter motors, and photovoltaic panels. And Sonobond's ultrasonic metal welders are also frequently used to close HVAC tubing, replacing crimp and solder methods.

Click here to download our free "Ultrasonics for Metals" brochure, containing an overview of Sonobond's ultrasonic metal welding expertise, equipment, and capabilities.


View the metal welding demo video

Vídeo de Soldadores Metálico