Sonobond Offers a Variety of Ultrasonic Equipment for Manufacturing Applications in the Defense and Aerospace Fields

Two Sonobond Machines-the Dual Head SpliceRite(TM) and the SeamMaster(TM) High Profile Textile Bonder-will be Exhibited in Booth #4195 at the AeroCon Show in Anaheim, California on February 12-14, 2013.

WEST CHESTER, Pennsylvania- Sonobond Ultrasonics announced today that it will be exhibiting at the AeroCon Aerospace & Defense Show next month in Anaheim. In making the announcement, Sonobond's President, Janet Devine, said, "This is the premier advanced manufacturing exhibition for these important industries, so we are excited about participating. Ultrasonic joining is often the method of choice in the automobile industry, and many companies in defense and aerospace have similar applications. We want to promote our ultrasonic solutions to these firms. For example, ultrasonic welders assemble aluminum and other non-ferrous metal products, wire harnesses, electrical devices, batteries, textiles, filters, aircraft insulation, body armor, and protective clothing, plus additional items with aerospace/aviation or military applications.

"Sonobond has a broad selection of ultrasonic bonding and welding equipment. We've selected two of our machines-the Dual Head SpliceRite Wire Splicer and the SeamMaster High Profile Textile Bonder-to exhibit at the AeroCon Show. I encourage attendees to come to Booth #4195 in the Anaheim Convention Center to see this equipment and learn more about the important advantages our ultrasonic technology provides to manufacturers in the defense and aerospace fields. Visitors to our booth will also be able to discuss how our ultrasonic welders and bonders can be customized to meet their company's specific needs."

The Dual Head SpliceRite Ultrasonic Wire Splicer

The Dual Head SpliceRite-one of the two units Sonobond will have on display at AeroCon-has two welding heads, one on each side of the welding area. This gives it a much greater capacity than typical ultrasonic metal welders that can usually accommodate wire bundles up to 40 sq. mm This dual-head technology comfortably splices cross-sectional areas up to 100 sq. mm with just one pulse. No other ultrasonic unit available today can equal this capacity with a single hit. Even tinned wires up to 60 sq. mm can be accommodated by the machine. Only Sonobond machines can weld tinned metals-without pre-cleaning!

The Dual Head SpliceRite Ultrasonic Wire Splicer consists of two ultrasonic transducers and couplers-one above and one below the weld area-plus a set of pneumatically driven jaws. The jaws gather the wires tightly to a preset width. The upper tip then descends to complete the compressing of the bundle and ultrasonic power is applied. When the cycle ends, the jaws open so the wires can be removed. The result is a solid-state metallurgical bond with high conductivity. There is no need for filler materials or for clipping, soldering, crimping, or dipping. The process is accomplished without arcs, sparks, or fumes and without melting the assemblage.

This Sonobond ultrasonic welder features heat-treated, tool steel taper lock tips that can last for 100,000 welds or more. These tips are designed for quick tooling changes and fool-proof placement. There is also a 3500-watt power supply with a built-in microprocessor that stores and recalls up to 250 jobs, permitting welds to be controlled by height, energy, or time. The process is fast, environmentally-friendly, and cost-effective. It has the advantage of using minimal energy while producing no waste.

Other Sonobond Ultrasonic Metal Welders

Sonobond spot welders, the WeldMaster(TM) C-Frame I and the WeldMaster(TM) C-Frame II, are very effective in accommodating large metal parts, such as those used in the aviation industry. These machines-with outputs of 2500 watts of power-can weld non-ferrous similar and dissimilar metal assemblies. At the same time, they virtually eliminate the problem of tips sticking to aluminum parts. The C-Frame I has a 14-inch throat depth and usually completes the weld operation in less than 1.5 seconds. The C-Frame II has an 18-inch throat depth and is available with a single or double head, which further expands the thickness range of weldable materials. The C-Frame welders are suitable for robot operation.

Made in the U.S.A.

All Sonobond metal welders are manufactured in the United States and feature the unique Wedge-Reed 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 precise, dependable welds without bending stress or stalling. The patented Wedge-Reed system also lets Sonobond equipment accommodate most tinned and oxidized metals without pre-cleaning. Sonobond machines are the only ones that have this capability.

The SeamMaster(TM) Series of Ultrasonic Bonders

Sonobond's SeamMaster ultrasonic bonders are similar in appearance and operation to traditional sewing machines. However, they use no thread, glue, or other consumables. Instead, they seal, "sew," and trim nonwoven and synthetic fabrics with ultrasonic vibration in just one step. Stitch holes or glue gaps are eliminated, as is fraying and/or unraveling of bonded edges.

The SeamMaster operates four times faster than conventional sewing machines and up to ten times faster than adhesive methods. They are the only ultrasonic bonders that feature a continuous-bonding rotary system. This enables them to bond more efficiently, reliably, and quickly than other "plunge" type ultrasonic bonders. They are frequently used to assemble filters and protective products, such as medical disposables that must comply with tough OSHA regulations for barrier seams. Sonobond offers a large selection of interchangeable pattern rollers for slitting, embossing, and "stitching."

Sonobond Equipment Helps Protect Aircraft and America's Military

An important member of the SeamMaster family, the SeamMaster High Profile Ultrasonic Bonder, will be the other Sonobond machine on display at the AeroCon Show in February.

Because this machine has a higher clearance between the wheel and horn than other SeamMaster units, it is ideal for hand-guided applications with tight tolerances, for heavy and bulky materials, and for working around curves. For example, this machine is used to fabricate insulation blankets, such as those supplied to Boeing Aircraft. Insulation blankets are custom-made to fit between the outer and inner skin to help keep the heat in the aircraft. The SeamMaster High Profile easily accommodates the different shapes and sizes required to fit around the doors, port holes, etc.

Companies also use this model to seal the outer shell of body armor with ballistic-resistant materials inside. This helps manufacturers comply with current National Institute of Justice submersion standards (NIJ 0101.06) requiring a leak-proof seam, even after water immersion for 30 minutes. These latest requirements are much
more stringent than previous standards that only mandated protection from a spray shower.

In commenting on this machine, President Devine, says, "We're very proud that Sonobond equipment is used in the production of so many products used by the defense and aerospace industry. But we are especially pleased by the important role our SeamMaster High Profile Bonder plays in assembling the body armor that helps protect America's fighting men and women, as well as law enforcement personnel and first responders."

A Commitment to Quality Service

Sonobond offers a free Ultrasonic Welding Viability Test to help confirm which machine is best for a specific application. Ms. Devine explains, "We gladly provide sample welds made on our equipment. We do this using materials supplied by the prospective customer. There is no obligation for this service. Then, once a company makes the decision to purchase, we work closely with them to customize our equipment to their specific requirements. Every effort is made to assure that the installation process will be as smooth and expeditious as possible. In addition, we send a Sonobond technician to provide first-time buyers with operator and maintenance training. This service is free to companies located in the United States or Canada. If the purchaser is overseas, we only ask that they cover the technician's travel costs and living expenses while there. In other words, companies can count on Sonobond for top-quality technical support and reliable customer service every step of the way-before, during, and after installation."

Industry Leaders Since 1960

Fifty-three years ago, Sonobond-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. Over the intervening years, the company has continued to earn an outstanding reputation for its pioneering work, innovative equipment, and quality engineering. Today Sonobond manufactures a complete line of ultrasonic bonding and welding equipment for firms in the aerospace, defense, body armor, automotive, appliance, solar, electrical, medical, and apparel industries. In addition to stand-alone and bench-mounted models, most equipment is also available in modular form suitable for integration into an assembly line.

A Special Invitation to AeroCon Attendees

President Devine encourages those coming to Anaheim for the AeroCon Show, February 12-14, to visit the Sonobond exhibit. She says, "As I've explained, our ultrasonic metal welders and textile bonders are important to the production of many products for the defense and aerospace field. So we encourage attendees to stop by Booth #4195 to learn more. Not only will visitors have the opportunity to see our Dual Head SpliceRite Ultrasonic Wire Splicer and our SeamMaster High Profile Ultrasonic Bonder, but we welcome the opportunity to answer questions about our equipment and how it can be customized to their company's specific needs."

For More Information

To learn more about Sonobond equipment or find out how to take advantage of the free, no-obligation Ultrasonic Welding Viability Test, please visit the company's website at or call 1-800-323-1269. For questions or immediate service, please contact Sonobond's Vice President, Melissa Alleman, at


Janet Devine



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