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Ultrasonic metal welding is one of the most important joining technologies employed in the manufacture of wire harnesses for the automotive, construction equipment and household appliance industries. Among other things, the process is used for joining multiple wires with each other as well as for joining wires with grounding terminals or high-current contacts. The wire cross-section sizes which can be ultrasonically welded ranges from 0.08 square millimeters to 200 square millimeters. Compared with crimping or resistance welding, ultrasonic welding offers numerous advantages. These include the excellent electrical properties of the joint, extremely low energy consumption and comprehensive process control and corresponding process data management.

Application variant


Large cross section / Energiebackbone

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Cu Wire to 90° High current contact from the reel

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Large cross section / Energiebackbone

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Cu Wire to High current contact

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Al Wire to 180° High current contact from the reel

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Cu Wire to 180° High current contact from the reel

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Al Wire to 90° High current contact from the reel

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Large cross section / Energiebackbone

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Al Wire to Cu plate

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Al Wire to brass plate

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Inline splicing

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End or butsplicing of Cu Wire

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Inline splicing of Al Wires

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Power distribution / low voltage

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Cu Wire to Cu cable lug

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Al Wire to Cu cable lug

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Al Wire to brass Terminal

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Al Wire to Terminal with insulation crimp

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Al Wire to Terminal with insulation crimp

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Al Wire to 180° terminal from the reel / single

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Large cross section / Energiebackbone

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Large cross section / Energiebackbone

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Ground Terminal

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