Sonobond's Exclusive Ultrasonic Machinery for Splicing Tin-Coated Wires will be Demonstrated at the Electrical Wire Processing Expo, May 2014

Patented Wedge-Reed system enables unique one-pulse welding without pre-cleaning.

WEST CHESTER, Pennsylvania — Sonobond Ultrasonics announced today that its equipment has distinct capabilities unmatched by any other ultrasonic metal welding or splicing machine.

"We produce the only ultrasonic system able to reliably weld most oxidized and tinned metals in one pulse without pre-cleaning," notes Sonobond Vice President Melissa Alleman.  "Thanks to our exclusive, patented Wedge-Reed bonding system, none of our competitors can offer that kind of fast, reliable splicing capability."  She adds, "We are also the first company with an ultrasonic splicer capable of welding stranded copper wire bundles of up to 100 square millimeters in a single pulse."  

Sonobond will demonstrate its SpliceRite™ Wire Splicer and feature a video of its patented ultrasonic metal welding and splicing technology at the Electrical Wire Processing Expo, May 14-15, Booth #1644, Wisconsin Center, Milwaukee.  It will also showcase samples of the variety of wire bundle splices that its equipment can accommodate.

Superior Ultrasonic Welding Using the Wedge-Reed System

Ultrasonic metal welding occurs when high-frequency vibrations are directed at components under a moderately high clamping force.  This creates a rapid build up of heat that produces a weld in just seconds and without significant melting of the base materials.  The result is a solid-state metallurgical bond created without excessive heat, current or consumables.

Sonobond's innovative Wedge-Reed bonding system maximizes the effectiveness of ultrasonic metal welding by combining high vibratory force with low amplitude coupling.  Utilizing shear mode vibration parallel to the welding surface and a line of force directly over the parts to be welded, the Wedge-Reed system ensures precise dependable welds without bending, stress or stalling.  In addition to joining most oxidized and tinned metals without any cleaning process, this welding method also accommodates thin-to-thin or thin-to-thick material welding, while still producing bonds with high conductivity.

Ultrasonic Equipment for Single-Pulse Welding of Tinned Wires

Sonobond's SpliceRite Wire Splicer – on display at Booth #1644, at the Expo – produces splices in wire bundles up to 60 square millimeters in size.  In just one pulse, it can handle tinned or oxidized wire bundles up to 35 square millimeters.

Sonobond's Dual Head SpliceRite Ultrasonic Wire Splicer can accommodate lightly tinned or oxidized wires up to 60 square millimeters without pre-cleaning.  Also, it's the only ultrasonic splicer with upper and lower welding heads, allowing it to weld stranded copper wire bundles of up to 100 square millimeters in a single pulse.   This makes it ideal for assembling heavy-duty cables used for trucks, cars, trains, industrial machinery and similar applications. 

Both the SpliceRite™ and the Dual Head SpliceRite™ feature easily and economically replaceable tool steel Taper Lock Tips that can last up to 100,000 welds and that require no recalibration, along with a microprocessor that stores and recalls up to 250 jobs.  Plus, Sonobond's equipment is easy to operate, requiring only minimal training.

"In addition to welding tinned or oxidized wires, our complete line of ultrasonic metal welders is being utilized in an increasingly wide variety of applications, including welding wire-to-wire and wire-to-terminals for electrical wire harnesses and bus bars and welding the terminals of lithium-ion batteries, foil-wound capacitors, thin aluminum or copper foil and electrical contacts," says Alleman.  Sonobond's metal welders are also involved in manufacturing fuses/circuit breakers, ignition modules, starter motors, photovoltaic panels, HVAC tubing and large metal parts for automotive assembly.

Free Ultrasonic Welding Viability Test

For companies weighing the advantages of ultrasonic metal welding and seeking to meet challenging customer specifications, Sonobond offers a free, no-obligation Ultrasonic Welding Viability Test.  After discussing the details of their applications, companies submit their materials for sample welds, allowing Sonobond's technical staff to determine the proper equipment and any tooling customization needed to satisfy specific production welding requirements.

"We're committed to providing outstanding customer service and technical support throughout the process," says Alleman.

More than a Half-Century of Industry-Leading Innovation

Since it received the first patent ever awarded for ultrasonic metal welding in 1960 as a company then known as Aeroprojects, Sonobond has maintained its well-earned reputation for innovative, quality-engineered products.  It currently manufactures ultrasonic welding and bonding equipment for the automotive, solar, electrical, filtration, aerospace, medical, body armor, and apparel industries.  Notes Alleman, "We take special pride in manufacturing all our metal welders in the United States, making them environmentally friendly, and maintaining the highest standards of quality and performance."

Learn More About Sonobond

See Sonobond at the Electrical Wire Processing Expo, Booth #1644.  If you're unable to attend the show, visit us online at to view our video and complete line of ultrasonic welding products, request information or inquire about our free Ultrasonic Welding Viability Test.  For more immediate service, please call 1-800-323-1269 or contact Sonobond's Vice President Melissa Alleman at

1191 McDermott Drive, West Chester, PA  19380

Phone:  610-696-4710   

Fax:  610-6920674




Melissa Alleman

Vice President


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