The Dual Head SpliceRite(TM) Ultrasonic Wire Splicer Is a Prime Example of Sonobond's Leadership in the Development of Innovative Welding Technology

This ultrasonic metal welder can confidently handle stranded wire bundles of up to 100 square millimeters with just one pulse.  Visitors to the 2013 National Electrical Wire Processing Technological Expo in Milwaukee (May 8-9) can see this machine in Booth #1642.

WEST CHESTER, Pennsylvania — Melissa Alleman, Vice President of Sonobond Ultrasonics, announced today that Sonobond will be in Milwaukee, Wisconsin on May 8 and 9 for the 2013 National Electrical Wire Processing Technology Expo.  She said, "We are very pleased to once again be exhibiting at this important event that draws industry decision-makers from all across the United States and from many other countries.  I invite those attending the Expo to visit us at Booth #1642 in the Delta Center.  This will give them the opportunity to see our Dual Head SpliceRite™ Ultrasonic Wire Splicer in action."

"Development of this high-performance machine—the most recent in our SpliceRite™ series—resulted from Sonobond's pioneering efforts in the area of dual head ultrasonic welding technology.  This ultrasonic equipment can reliably weld stranded copper wire bundles having cross-sections of 48 to 100 square millimeters.  It even accommodates lightly tinned or oxidized wires up to 60 square millimeters without pre-cleaning.  No other ultrasonic metal welder can accomplish these splices in a single pulse.  These advantages make the Dual Head SpliceRite ideal for fast, dependable, cost-efficient ultrasonic splicing of the heavy-duty cables used in wire harnesses for cars, trucks, trains, industrial machinery, and similar applications."


Development of the Dual Head SpliceRite resulted from the company's earlier work on dual head ultrasonic welding technology for the automotive industry. 

In the years between 2004 and 2008, Sonobond Ultrasonics was involved in a NIST ATP project with Ford Motor Company and others.  At that time, the automotive industry was looking for ways to weld various aluminum alloys at sheet thicknesses up to two layers of 3 mm each.  However, the available ultrasonic welder power delivery capabilities were limited.  This necessitated a lengthy weld time that resulted in sticking between the welding tip and the aluminum.  Sonobond began working on a solution.  The result was the Dual Head Ultrasonic Spot Welder.  This machine was able to bring power to the weldment from upper and lower tips and weld the desired thickness of metal in shorter welding times, substantially reducing tip sticking.  The success of the Dual Head Spot Welder then encouraged Sonobond to look for a way to apply this technology to ultrasonic wire splicing, which led to the development of the Dual Head SpliceRite Ultrasonic Wire Splicer.

The Dual Head SpliceRite features two ultrasonic transducers and couplers, one above and one below the wire bundle.  In addition, there is a set of pneumatically driven jaws that 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 has been completed, the jaws open so the wires can be removed.  A support for the wire array can also be integrated into the tooling if necessary.

In commenting on this important advancement in ultrasonic welding technology, Vice President Alleman says, "Development of the Dual Head SpliceRite has enabled us to add yet another innovative machine to our line of cost-effective, environmentally-friendly metal welders that produce exceptional results.  Visitors to the National Electrical Wire Processing Technology Expo will be very impressed when they come to Booth #1642 and see this ultrasonic wire splicer in action.  Like all our other ultrasonic metal welders, this machine is made in the U.S.A.  And, like other Sonobond equipment, it can be operated easily with only minimal training." 

A Popular and Effective Welding Process

Ultrasonic welding is an increasingly popular method for assembling wire harnesses.  This process creates solid-state metallurgical bonds that have high conductivity.  It does this without producing arcs, sparks, or fumes and without melting the metals.  This is especially significant in the case of the Sonobond Dual Head SpliceRite Wire Splicer with its two ultrasonic heads, one on each side of the welding area.  As a result of this dual-head capacity, stranded copper wire—with cross-sectional areas of 48 to 100 sq. mm—can be welded with a single pulse.  No other ultrasonic machine can equal this capacity with just one hit.  Even tinned wires up to 60 sq. mm can be accommodated without pre-cleaning.

All Sonobond spot welders, including the Dual Head SpliceRite, use 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 precise, dependable welds without bending stress or stalling.  It is also enables most oxidized and tinned metals to be spliced with one pulse and without pre-cleaning.  No other ultrasonic metal welding system can consistently weld oxidized or tinned surfaces.


The Dual Head SpliceRite features heat-treated, tool steel taper lock tips that can last for 100,000 welds or more.  These are designed for quick tooling changes and help ensure fool-proof placement with no need to recalibrate.  The equipment has a 3500-watt power supply with a microprocessor that stores and recalls up to 250 jobs. Welds can be controlled by height, by energy, or by time.

Over a Half-Century of Innovation

In 1960, Sonobond—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding.  Over the intervening 53 years, Sonobond has continued to enjoy a well-earned reputation for its pioneering work and quality-engineered products.  Sonobond currently manufactures a complete line of ultrasonic welding and bonding equipment for firms in the automotive, appliance, solar, electrical, filtration, aerospace, medical, body armor, and apparel industries.

Free Ultrasonic Welding Viability Test

Sonobond recognizes that manufacturers and assemblers need to confirm that ultrasonic welding is appropriate for their specific application(s).  So it offers a no-cost Ultrasonic Welding Viability Test.  This gives companies the opportunity to submit their materials to Sonobond to have sample welds made.  Once a manufacturer decides to introduce Sonobond equipment into its production process, every effort is made to ensure that this is accomplished in as seamless a manner as possible.  Sonobond also backs its equipment with superior customer service and provides prompt, dependable technical support before, during, and after installation.

Those coming to Milwaukee for the National Electrical Wire Processing Technology Expo (May 8-9) are encouraged to visit Sonobond at Booth #1642 to see the Dual Head SpliceRite.  A short video showing this equipment in operation is also available on the company's website at This website has details about Sonobond's complete line of ultrasonic metal welders, as well as information on how to take advantage of the free, no-obligation Ultrasonic Welding Viability Test.

For questions or immediate service, please contact Sonobond's Vice President, Melissa Alleman, at or by calling 1-800-323-1269. 

© 2013 Sonobond Ultrasonics

1191 McDermott Drive

West Chester, PA 19380

Phone: 610-696-4710  

Fax: 610-692-0674




Melissa Alleman

Vice President


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