Efficient joining technologies play a central role in the modern manufacturing of busbars. Especially in the manufacture of busbars, which are used in power distribution systems, electric vehicles and other high-current-carrying applications, choosing the right joining technology is crucial for product quality, production efficiency and cost structure.
How ultrasonic bonding makes hygiene products more eco-friendly
Legal requirements and changing consumer behavior make sustainable production methods in diaper manufacturing a necessity. At the same time, companies are under pressure to optimize their costs and remain competitive. Ultrasonic welding offers an innovative solution that combines ecological and economic advantages.
Manufacturing adhesive-free hygiene products with ultrasonics
Manufacturers of hygiene products such as diapers are constantly under pressure to reduce costs while delivering high-quality products. One effective long-term method of meeting these requirements is to use ultrasonic bonding instead of conventional adhesives. This efficient joining method offers significant advantages in terms of cost savings, efficiency, and sustainability.
This webinar is for manufacturers of medical wearable devices such as CGM systems, infusion sets, and insulin pumps. It explains how these types of products can specifically benefit from ultrasonic welding technology in both low- and high-volume manufacturing. You will learn how the process works and how it creates hermetic seals for your individual application with a safe, reliable, and traceable process.
Explore the versatility of continuous ultrasonics! Learn how mechanical vibrations create soft, adhesive-free bonds for delicate welding in hygiene, medical, and nonwovens. Explore lamination, cutting, and wide-web applications.
How ultrasonics optimizes the manufacturing of hygiene products
Diapers are an indispensable companion for babies or adults with incontinence problems. In addition to key aspects such as absorbency and leak protection, wear comfort is becoming increasingly important when selecting the right diaper. Consumers are paying more and more attention to products that feel soft on the skin and are comfortable to wear.
The softness of nonwoven materials plays a decisive role here. But how can the softness of the nonwoven material be preserved during the manufacturing of diapers and other hygiene products? Choosing the right bonding process is a key factor.
Herrmann Ultrasonics is thrilled to announce the grand opening of its newest Tech Center and laboratory in Monterrey, Mexico, on April 24, 2025. With over 60 years of pioneering German-designed ultrasonic technologies, this milestone marks a significant step in bringing the latest innovations closer to manufacturers and industry leaders in Mexico and beyond.
World Diabetes Day: Advancing the Future of Wearable Medical Technology
World Diabetes Day is a time to recognize the challenges faced by millions living with diabetes and celebrate the innovations that improve their lives. Herrmann Ultrasonics is committed to advancing wearable medical technology, supporting the production of cutting-edge devices that help patients manage diabetes safely, comfortably, and effectively.
Automated connection of medical components for maximum output
Perfect for automated assembly: Thanks to minimized welding times and real-time process control, ultrasonics is ideal for manufacturing medical components in high volumes. Find out the advantages of the technology for your application in this article.
Joining Plastics of Medical Devices Without Adhesive
Particularly for medical products with direct skin contact, high wear comfort and skin compatibility are crucial for the quality of the product and customer satisfaction. Manufacturers should therefore avoid chemicals such as IBOA and connect plastics with processes that do not require adhesives, solvents or environmentally harmful substances - ultrasonics make this possible.
The switch from PVC to thermoplastic elastomers (TPE) in medical technology promotes health and environmental protection. TPE is phthalate-free, biocompatible and easier to recycle, which reduces the risks of allergies and environmental pollution. Despite challenges in joining TPE, ultrasonic welding offers an effective solution for stable and durable joints. This step improves product quality and minimizes health risks in the medical industry.
Joining medical applications quickly and sustainably with ultrasonics
Connecting plastics without adhesives: Using ultrasonics as a joining technology, companies can produce their applications skin-friendly and eco-friendly. If certain specifications for the components are met, the process can also be used for sensitive applications with complex geometries.
At Herrmann Ultrasonics, we believe that feedback is a gift. As part of our ongoing efforts to improve customer experience, we've introduced a new Customer Satisfaction Survey.
New process: Sealing uncoated paper with ultrasonics
Ultrasonic sealing of uncoated paper is a joining process that is as innovative as it is environmentally friendly, enabling packaging companies to save significant amounts of energy and resources. Patent holder Syntegon Technology GmbH recently handed over exclusive rights to the process to Herrmann Ultraschall. The company wants to move the process to market maturity and establish it in the packaging industry.
With the SLIMLINE systems, Herrmann Ultraschall offers the ideal welding solution for the automation of production processes. In addition to increased cycle rates, companies benefit from consulting with Herrmann Engineering, which enables rapid integration into production lines.
Herrmann Ultraschall is expanding its management team with André Deponte as the new Chief Sales Officer. With digital processes and an even closer relationship between the global sales teams, he wants to create a consistent and exciting customer experience worldwide.
Having the chance to be involved in the development of an ultrasonic welding machine: for Norbert Ennemoser from Ultra Reflex GmbH, Germany, this wish has come true. He was able to put the new HiQ machine generation from Herrmann Ultraschall through its paces for eight weeks as part of a field test. A collaboration that generated a lot of excitement on both sides.
Sustainable and efficient sealing with the new TSM
Save energy and material permanently: with the TSM Top Seal Module Herrmann Ultraschall offers a simple solution for sealing packaging materials more efficiently and reliably. Thanks to the new solution for sealing the hermetic and cosmetic seal at the same time, companies can also reduce the size of their packaging machines.
Ultrasonic sealing and heat sealing are the two most common methods used for sealing in packaging and manufacturing today. What are these processes, and why do facilities choose one over the other? We will examine ultrasonic sealing vs. heat sealing in greater depth throughout this piece, first defining each one:
Flawless appearance was the major challenge in welding an oval, three-dimensional half case for a consumer product. A joint development process between BSH and Herrmann Ultraschall succeeded in meeting these requirements while also providing strong joints.
With the newest generation of the sound-insulated welding machines ULTRASAFE, Herrmann Ultraschalltechnik GmbH & Co. KG offers an ergonomic manual workstation with a larger engagement range and adjustable lifting door.
It’s a space-saving and sustainable solution for sealing hermetic and cosmetic seals on stand-up pouches: with the COS upgrade for the top seal module TSM from Herrmann Ultraschall, manufacturers of packaging machines will be able to perform several work steps in just one sealing station.
Systems from Herrmann Ultraschalltechnik GmbH & Co. KG reduced the reject rate for CUSTOMCELLS® during the production of a new battery application and thus increased efficiency for this manufacturer.
Herrmann's Elastic Thread Anchoring (ETA) Sonotrode has been awarded the prestigious IDEA Equipment Achievement Award 2022. With this prize, the nonwovens association INDA honors the best technical developments in the industry.
Herrmann Ultraschalltechnik GmbH & Co. KG is optimizing its global structures, and has made André Deponte the new head of international headquarters. Deponte is to oversee closer global collaboration to ensure a standard customer experience around the world.
For the producers, manually inserting 18 brass female connectors into a plastic frame for a control unit was a laborious and costly process. Ultrasonic welding offered an efficient alternative which considerably shortened the cycle times and was also financially worthwhile – in spite of a lower unit count. The versatility of the sonotrode and HERRMANN ENGINEERING played a crucial role here.
The insertion of elastic threads can be complex and costly in the manufacture of hygiene products. Herrmann Ultraschalltechnik GmbH & Co.KG, Karlsbad, Germany, has developed a novel patented method for fixing elastic threads that simplifies handling, reduces the risk of breakage, enlarges the process window and lowers production costs.
Booming electromobility and the growing demand for fast charging technologies result in increasing system voltages for electric vehicles. This requires powerful cable harnesses and power rails, which in turn requires larger cable cross sections and/or metal sheet thicknesses. The higher the cross section, the more difficult the welding. For this purpose, Herrmann developed the Ultrasonic Power Stack 12000+ as an extension for their HiS VARIO W ultrasonic welding machines.
Battery management systems (BMS) for cylindrical cells require precisely adjustable low weld forces. Herrmann has developed a new module which suits especially the welding of BMS to small cylindrical cells and finest materials, that can easily be integrated in existing production processes.
Welding of materials within milliseconds, according to type
Plastic products and packaging will still play a major role in future. However, the aim is to use and reuse this valuable material as long as possible. Sustainable processing by ultrasonic welding helps reach this aim.
This year has been challenging, but we are very grateful that we could contribute to the fight against COVID-19 with our ultrasonic technology for face masks and breathing ventilators. And it is in this sense of gratitude and hope that we once again decided to support worthy causes this Christmas
Together with the packaging service provider Verdesoft, Herrmann Ultraschall has developed a cup and a tube that can be closed by ultrasonics. The packaging concepts have a comparable product protection as conventional plastic packaging and save up to 75% plastic.
This is the famous Building M where CEO Thomas Herrmann studied mechanical engineering at the Karlsruhe University of Applied Sciences from 1984 to 1989. Now the university has appointed him to the university council as alumnus and head of a family-owned yet globally operating technolgy company.
As anniversary celebrations go Herrmann Ultrasonics could not ask for a better way to ring in 30 years of ultrasonic welding in the US. The company was recently named by the Daily Herald as one of the best small companies in IL to work. Herrmann has grown from a small start-up to an industry leader with a strong global presence in ultrasonic engineering, continuing to stretch their wings.
Thomas Herrmann is a manager, a maker and shaker and a philanthropist. He is a man who has also appeared on stage as an actor in front of thousands of visitors to the cult musical "Weihnachten neu erleben" (bringing back the Christmas spirit), to inspire enthusiasm for the charitable cause.
Process control in ultrasonic welding for medical sector
In the fight against the corona virus, ventilators and corona tests have come to the fore. Herrmann Ultraschall supplies well-known manufacturers with the welding technology to assemble the necessary components such as mouth and nose contact pieces, floats, filters and housings. The two software tools FSC and SonicCalibrate developed by Herrmann play an important role for quality assurance in the ultrasonic welding process.
At this year's Spring Challenge of the Karlsbad Municipality in southern Germany, we took third place in the category Bike Commuters Baden Württemberg with a team of 10 colleagues and 224 km per team member. In total, our team covered 2,462 km and saved 362 kg of CO2.
The Lower Saxony-based automotive supplier Zender Group, Osnabrück, specializes in carbon and textile products. The company recognized the need for personal protective equipment at an early stage and started to set up a mask production facility in record time.
Herrmann Ultraschall provides Arburg with a HiQ VARIO ultrasonic welding system free of charge for the Lossburg-based company's large mask project (see press release).
Herrmann Ultraschall has been a specialist in ultrasonic welding for decades and has set high goals with the new weld system HiS VARIO for battery and terminal applications: in addition to process stability, these are shorter setup times and longer service life for the weld tools, above all.
Mono-materials and paper composites for packaging are increasingly in demand and the number of inquiries regarding new recyclable materials is increasing at the ultrasonic laboratory of Herrmann Ultraschall. Many of the major food companies have set themselves high sustainability targets and are testing the new materials.
The use of softness-enhancing Air-Through Bonded materials (ATB) is increasing – typical hygiene applications are acquisition distribution layers (ADL), waist panels, and top sheets. Ultrasonic welding can offer process related and environmental advantages over glue and heat bonding. The nonwovens laboratory at Herrmann Ultraschall provides high-tech support for application solutions when it comes to bonding ATB.
The ultrasonic welding of nonferrous metals is an established process and is currently booming in connection with the growing market for lithium-ion batteries (LIB) – now the main storage source for electromobility. Herrmann Ultraschall has been a specialist in ultrasonic welding for decades and has now developed a new weld system for metals, the HiS VARIO.
Herrmann Ultraschall supplies the ultrasonic welding technology for the production of different face masks. Inquiries accumulate. Focus on short transport distances.
After nearly 30 years in the US market, we are expanding the area of our Bartlett, Illinois, facility to 2,800 m². The expansion should support the planned growth of Herrmann Ultrasonics in the new decade, create additional production space and enable stronger employee growth.
Herrmann Ultrasonics, Inc. expands to support continued growth and sales
Herrmann Ultrasonics is pleased to announce that they are currently in the process of adding 10,000 square feet to their US headquarters in Bartlett, IL. After almost 30 years in the US market, the ultrasonic manufacturer will increase its footprint to 30,000 square feet.
This year's Christmas donation in the context of our charity initiative “Herrmann Cares” is intended for education and goes to two schools in Karlsbad, Germany, to make subject-related project days affordable for all students.
Herrmann Ultrasonics has been named the winner of the Electrolux Supplier Innovation Award for Food Preservation. The company was awarded the top honor out of an initial 40,000 suppliers world-wide at the annual Supplier Awards event, held in Stockholm a few weeks ago.
Herrmann Ultraschall has been a specialist in ultrasonic non-ferrous welding for decades and is presenting its new HiS VARIO welding system for metal welding such as copper and aluminum at Productronica. The system can be used as a manual workstation or automatically integrated into production lines.
As of now there are few inquiries for the welding of recycled materials, ie plastics that already have been processed once or more before. The weldability must be determined empirically in the test laboratory.
Ultrasonic technology can also deliver good sealing results with narrow process limits, especially with regard to tightness and visual appearance. The thermal expansion is kept to a minimum. Thermal processes demonstrate disadvantages of excessive heat input, especially in the continuous welding of film webs.
Ultrasonics for cuff elastic is a relatively new topic. How were they processed before?
What is the most important aspect of thread processing?
What role does the rotary anvil play?
Where is this trend leading?
By means of the ultrasonic process, multilayer absorbent bodies, e.g. a diaper, including the SAP granules (Super Absorbent Polymer) can be welded glue-free and in one single step. Now Herrmann Ultraschall offers an innovative process for elastic cuffs.
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