Applications

The ultrasound is used to realise a variety of applications, among other things cutting, welding, punching and riveting of plastics and textiles. The process offers many advantages over other joining methods. An important factor is the flexibility of the systems, which are designed for many different applications and requirements. Furthermore, it is a very energy efficient process.

Applications Cutting

For clean cutting edges without sticking and material distortion

Cutting

The cutting tools are excited with ultrasound, which requires significantly less cutting force. The ultrasonic blades cut like a hot knife through butter. This process involves a microscopic sawing movement. On the one hand, this allows cutting materials which are difficult to separate and, on the other hand, prevents substances from adhering to the tool by reducing the friction. In this way, tough materials such as rubber or cheese can be cut without sticking and material distortion. Depending on the design of the tool, a local temperature increase at the cutting edge may occur, so that the cutting edges are simultaneously sealed when cutting. During this, the tool remains cool.

Textiles are cut with the help of ultrasound.

Materials Cutting

Metals

The process of ultrasonic metal welding differs from that of plastic processing in that the force and oscillation direction of the tools differ. Basically, non-ferrous metals such as aluminium, copper and some alloys can be joined by ultrasound - for instance in wire harnesses, batteries or solar absorbers. Find out more on the website of Schunk Sonosystems.

Plastics

Almost all thermoplastics can be processed with ultrasound. The higher the amount of thermoplastic, the better it will work to join or separate the material. The following applies: the more similar the properties of two joining partners, the better the connection. Additives such as glass or carbides limit the processability. We can examine your specific material in our ultrasound laboratory.

Composites

The efficient processing of honeycombs, glass or carbon fibres, prepregs and fibre-reinforced composite materials is a steadily growing market - driven by the increasing demands in lightweight engineering and high-tech industry. Ultrasonic processing tools are designed individually depending on the application, material and geometry.

Technical textiles

Technical textiles are fibres and textiles with thermoplastic materials. These materials are often very good for welding, sealing or separation by means of ultrasound. Process speed, strength, edge quality and appearance are significantly better than traditional methods like sewing, gluing or hot welding.

Products Cutting

For clean cutting edges without sticking and material distortion

Basic system

Ultrasound system consisting of generator, converter, booster and sonotrode

The basic system is designed for use according to the Plug&Play principle and can be easily applied at individual workstations, robots or automation systems. It is robust, modular and therefore very flexible.

Versions: 20 kHz, 35 kHz, 50 kHz

Ultrasound system consisting of generator, converter, booster and sonotrode

Roll seam systems

Rotating ultrasonic welding systems for continuous welding

Almost all textiles with thermoplastic materials can be continuously welded with the 35 kHz roll seam module. The appearance of the weld seam can be freely selected from invisible and conventional to personalized lettering. The 20 kHz roll seam system can also be used for welding aluminium and copper components.

Versions: 20 kHz, 35 kHz

Picture of an ultrasonic roll seam system with a table.

Feed units

Basic system including pneumatic lifting unit

Ultrasonic feed units are the simplest ultrasonic welding presses. Ready mounted on a pneumatic linear unit, the systems can be used for automation systems, multi-presses and almost all welding applications where a stroke axis is required.

Versions: 20 kHz, 35 kHz
 

Picture of an ultrasonic feed unit, the simplest ultrasonic welding press.

Applications Welding

The most energy-efficient joining process for plastics and textiles

Welding

During the ultrasonic welding of plastics and textiles, the thermoplastic constituents of the workpieces are heated locally above the softening point within a very short time. This creates an inseparable weld during compression. The local heating is generated by the contact pressure and the high pressure fluctuations that the sonotrode exerts on the workpiece. The tool and the surrounding components remain relatively cold. Due to the operation in resonance, the ultrasonic welding is one of the most energy-efficient joining processes because almost all the energy is introduced into the joining zone.

[Translate to English:] Nahaufnahme einer Ultraschallschweißung mit Rollnahtsonotrode

Materials Welding

Plastics

Almost all thermoplastics can be processed with ultrasound. The higher the amount of thermoplastic, the better it will work to join or separate the material. The following applies: the more similar the properties of two joining partners, the better the connection. Additives such as glass or carbides limit the processability. We can examine your specific material in our ultrasound laboratory.

Metals

The process of ultrasonic metal welding differs from that of plastic processing in that the force and oscillation direction of the tools differ. Basically, non-ferrous metals such as aluminium, copper and some alloys can be joined by ultrasound - for instance in wire harnesses, batteries or solar absorbers. Find out more on the website of Schunk Sonosystems.

Composites

The efficient processing of honeycombs, glass or carbon fibres, prepregs and fibre-reinforced composite materials is a steadily growing market - driven by the increasing demands in lightweight engineering and high-tech industry. Ultrasonic processing tools are designed individually depending on the application, material and geometry.

Technical textiles

Technical textiles are fibres and textiles with thermoplastic materials. These materials are often very good for welding, sealing or separation by means of ultrasound. Process speed, strength, edge quality and appearance are significantly better than traditional methods like sewing, gluing or hot welding.

Products Welding

The most energy-efficient joining process for plastics and textiles

Basic system

Ultrasound system consisting of generator, converter, booster and sonotrode

The basic system is designed for use according to the Plug&Play principle and can be easily applied at individual workstations, robots or automation systems. It is robust, modular and therefore very flexible.

Versions: 20 kHz, 35 kHz, 50 kHz

Ultrasound system consisting of generator, converter, booster and sonotrode

Roll seam systems

Rotating ultrasonic welding systems for continuous welding

Almost all textiles with thermoplastic materials can be continuously welded with the 35 kHz roll seam module. The appearance of the weld seam can be freely selected from invisible and conventional to personalized lettering. The 20 kHz roll seam system can also be used for welding aluminium and copper components.

Versions: 20 kHz, 35 kHz

Picture of an ultrasonic roll seam system with a table.

Feed units

Basic system including pneumatic lifting unit

Ultrasonic feed units are the simplest ultrasonic welding presses. Ready mounted on a pneumatic linear unit, the systems can be used for automation systems, multi-presses and almost all welding applications where a stroke axis is required.

Versions: 20 kHz, 35 kHz
 

Picture of an ultrasonic feed unit, the simplest ultrasonic welding press.

Welding Presses

Single workstations for welding plastic parts, textiles and metals

The ultrasonic welding press is a conventional single workstation on which workpieces are inserted individually or in a matrix and welded. It is operated via two-hand trigger mechanism or foot switch.

Versions: 20 kHz, 35 kHz

Picture of an ultrasonic welding press.

Hand-held device

Manual cutting and welding

The flexible hand-held device includes a full-featured ultrasound system, which, depending on the sonotrode selection, allows manual execution of all applications such as welding, cutting, riveting, punching, aerosolizing and dispersing.

Version: 35 kHz

Picture of an ultrasonic hand-held device.

Robots and CNC systems

Wide range of applications due to a programmable sequence

An ultrasound system on a programmable robot or a CNC-controlled table is used to precisely cut 2D or 3D contours or to weld or rivet complex geometries. 

Version: 35 kHz

Picture of a robot in combination with an ultrasound system.

Sonotrodes

Tools for a variety of applications

The design of a sonotrode strongly depends on the application and the process requirements. Each sonotrode has an individual design and is worked out by means of FEM simulation. Depending on the application, the sonotrodes are made of selected aluminium, titanium or steel alloys.

Picture of a sonotrode
Picture of a sonotrode that can be used for cutting and welding.
Picture of a welding sonotrode with special contours.
Picture of a cutting sonotrode
Picture of a roll seam welding sonotrode for aluminium and copper alloys

Applications Punching

Ultrasound allows punching without backing

Punching

The reduction of cutting forces and friction is used in ultrasonic punching to produce a clean, sealed cutting edge, as in ultrasonic cutting. When punching, the shape of the sonotrode is adjusted to the punching contour. The advantages over traditional punching are the sealing of the cutting edge and the possibility to punch into a free contour without a backing.

Circular punching in plastic material

Materials Punching

Plastics

Almost all thermoplastics can be processed with ultrasound. The higher the amount of thermoplastic, the better it will work to join or separate the material. The following applies: the more similar the properties of two joining partners, the better the connection. Additives such as glass or carbides limit the processability. We can examine your specific material in our ultrasound laboratory.

Metals

The process of ultrasonic metal welding differs from that of plastic processing in that the force and oscillation direction of the tools differ. Basically, non-ferrous metals such as aluminium, copper and some alloys can be joined by ultrasound - for instance in wire harnesses, batteries or solar absorbers. Find out more on the website of Schunk Sonosystems.

Composites

The efficient processing of honeycombs, glass or carbon fibres, prepregs and fibre-reinforced composite materials is a steadily growing market - driven by the increasing demands in lightweight engineering and high-tech industry. Ultrasonic processing tools are designed individually depending on the application, material and geometry.

Technical textiles

Technical textiles are fibres and textiles with thermoplastic materials. These materials are often very good for welding, sealing or separation by means of ultrasound. Process speed, strength, edge quality and appearance are significantly better than traditional methods like sewing, gluing or hot welding.

Products Punching

Ultrasound allows punching without backing

Basic system

Ultrasound system consisting of generator, converter, booster and sonotrode

The basic system is designed for use according to the Plug&Play principle and can be easily applied at individual workstations, robots or automation systems. It is robust, modular and therefore very flexible.

Versions: 20 kHz, 35 kHz, 50 kHz

Ultrasound system consisting of generator, converter, booster and sonotrode

Roll seam systems

Rotating ultrasonic welding systems for continuous welding

Almost all textiles with thermoplastic materials can be continuously welded with the 35 kHz roll seam module. The appearance of the weld seam can be freely selected from invisible and conventional to personalized lettering. The 20 kHz roll seam system can also be used for welding aluminium and copper components.

Versions: 20 kHz, 35 kHz

Picture of an ultrasonic roll seam system with a table.

Feed units

Basic system including pneumatic lifting unit

Ultrasonic feed units are the simplest ultrasonic welding presses. Ready mounted on a pneumatic linear unit, the systems can be used for automation systems, multi-presses and almost all welding applications where a stroke axis is required.

Versions: 20 kHz, 35 kHz
 

Picture of an ultrasonic feed unit, the simplest ultrasonic welding press.

Applications Cut & Seal

Cutting and sealing of the cutting edge in one step

Cut & Seal

Cut & Seal is used to cut thermoplastic textiles simultaneously and to weld them at the cutting edge. This means that materials can be joined together in multiple layers and with almost invisible weld seam. In this way, the two work steps of cutting and subsequent sewing or gluing of textiles are replaced by one. The result is an aesthetic clean cutting edge. If desired, the tools can be designed such as to produce an appearance of a conventional seam. 

Ultrasonically cut and at the same time sealed hem of a textile.

Materials Cut & Seal

Products Cut & Seal

Cutting and sealing of the cutting edge in one step

Applications Riveting

Inseparable combination of materials with different properties

Riveting

Ultrasound can also be used to inseparably connect materials with different thermoplastic properties. One of the components is provided with rivet heads, which are plasticized by ultrasonic energy. Ultrasonic riveting, like ultrasonic welding, is one of the most efficient and stable joining processes. Unlike gluing or classic riveting, no further auxiliary materials are needed.

Picture of rivet head sonotrode

Materials Riveting

Products Riveting

Inseparable combination of materials with different properties

Industries

Close-up of a car
Automotive

Cutting, Welding

Hand with stylized light bulb
Innovations

New application areas

Close up of technical textiles
Textile Industry

Cutting, Welding, Sealing, Cut & Seal

Close-up of a non-woven material
Non-wovens

Cutting, Welding, Cut & Seal

Close up of a plastic rear light for a passenger car
Kunststoffindustrie

Schneiden, Stanzen, Schweißen, Einbetten, Nieten

Close-up of a composite material (carbon fibres)
Composites

Cutting, Welding

Ultrasonic basics

Basic principles

There are basically two types of oscillations: for transverse waves, the oscillation direction is perpendicular to the propagation direction. Examples are strings of musical instruments or light in a vacuum.

The oscillation direction and the propagation direction of longitudinal waves are aligned. This is the case, among other things, with sound waves in gases or liquids. 

Idler frequencies

Because, in addition to the desired oscillations (usually longitudinal oscillations), further modes of oscillation are possible which are close to the operating frequency, the components may be subjected to undesired bending and torsion oscillations or mixed modes of oscillation. These modes prevent proper operation and lead in the medium term to the destruction of the tools. The more complex a sonotrode is, the more difficult it will be to exclude idler frequencies by FEM analysis and customized design.

Wavelength

Ultrasonic systems use longitudinal waves for energy transmission. To achieve an optimum energy yield, the systems are dimensioned in such a way that the resonance frequency of the individual components corresponds exactly to the applied operating frequency. This is the case if the length of the components is half a wavelength or a multiple thereof

Blog

News on applications, dates and innovations

Screenshot of Schunk Sonosystem Innovations' new website.

28.08.2019

New website

Discover our new content

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21.08.2019

New CNC lathe

Highly flexible production

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30.07.2019

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All news and innovations on the Schunk Sonosystems Channel

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01.02.2019

Name change

We are now called "Schunk Sonosystems Innovations"

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About us

What you should know about us: we manufacture in Germany, deliver everything from one source, live up to the culture of innovation and are constantly exchanging ideas with our customers.

Picture of the Schunk Sonosystems Innovations Team.

We think ahead – we offer both our standard ultrasound systems and customized solutions tailored to your applications.

Picture of the Schunk Sonosystems Innovations Team at its headquarter in Graevenwiesbach.

Who we are

Our team in Graevenwiesbach, Germany, is there wherever you need it. With technological expertise, decades of experience and a great deal of motivation, we will develop an ultrasound system which is suitable for your application. Simply contact us.

Drei alte schwarz-weiß Fotografien von Schwingersystemen.

History

Where we come from

Schunk Sonosystems Innovations was founded in 1985 under the name Ultrasonics Steckmann GmbH by Prof. Dr. Helge Steckmann. The former company’s headquarters were in Graevenwiesbach-Hundstadt. Ultrasonics Steckmann has successfully completed numerous projects in the ultrasonic welding of plastics and metals and gained recognition at national and international level among experts over decades. The development and construction of large plants for the solar industry necessitated opening of a second location, which was opened in 2006 in Graevenwiesbach and is now the only location of the company. In 2016, the Schunk Group acquired the company, thus supplementing the already existing portfolio in ultrasonic processing. Since 2019 Ultrasonics Steckmann operates under the name Schunk Sonosystems Innovations GmbH as a subsidiary of Schunk Sonosystems GmbH, the world’s market and technology leader in ultrasonic metal welding. As our partner, you are the first to benefit from great exchange of experience and innovation and from the bundled resources of both companies.

Picture of Sonosystems Innovations' headquarter

Where you can find us

Schunk Sonosystems Innovations GmbH

Thueringer Straße 19
61279 Graevenwiesbach
Deutschland

Phone
+49 6086 96990 

(Mo-Th 8 a.m.-3 p.m., Fr 8 a.m.-2 p.m.)

E-Mail
ultrasonics@schunk-group.com

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+49 6086 96990-20
valentin.muela@schunk-group.com

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Doris Frenes

Sales, Purchase, Administration

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+49 6086 96990-13
steve.schoener@schunk-group.com

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Alexander Manz

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+49 6086 96990-14
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