The optimum oscillation behavior of the ultrasonic sonotrodes is determined by means of FEM (Finite Element Method) calculation. Highest precision requirements in terms of CAD/CAM calculation algorithms guarantee precise 3D contours for sonotrode manufacturing. Measuring and documentation of the amplitude distribution is performed at the vibrating sonotrode using state-of-the-art laser measurement technology. Special surface finishings result in even longer service life spans of the ultrasonic sonotrodes.
The sonotrode, sometimes referred to as the sonotrode or ultrasonic welding horn, transfers vibrations into the part being welded. It takes precise design and careful manufacture to ensure the consistent results that users demand.
The most important aspects of ultrasonic horns are geometry and material. The shape of the horn governs how vibration is transmitted to the workpiece, as well as gain and amplitude achieved. These must be optimized for each application.
Titanium is preferred for high-volume ultrasonic welding applications, although in some cases where the plastic has abrasive properties, steel can be an attractive alternative. Aluminum is suitable for low-volume applications or extra-large sonotrode sizes.
Sonotrode application examples
Joining plastic components is one of the most common applications for ultrasonic welding. Consumer goods, toys and electronic products are just some of the industries using this technology. Many of these require cylindrical or block sonotrodes.
Packaging companies and textile manufacturers often use blade-style sonotrodes for sealing. The automotive industry, on the other hand, deploys many forms of sonotrodes to address the variety and complexity of welding tasks. The battery industry uses the same principles of ultrasonics and tooling design however the vibration is applied in a shearing plane.
The leading ultrasonic horn manufacturer
As one of the oldest companies in the ultrasonic welding industry, Herrmann Ultrasonics has an unmatched depth of knowledge and experience. From the simplest ultrasonic horn to complex assemblies for automated processing and assembly, Herrmann Ultrasonics can provide the components, systems and expertise needed for welding and sealing. This extends to our 360° ULTRASONIC ENGINEERING service, which helps manufacturers maximize their ROI in ultrasonic welding equipment.