20 kHz / 3000 Watt Ultrasonic Metal Welding Machine from Dhruv’s Ultrasonics is a precision-engineered solution built for high-quality bonding of non-ferrous metals such as copper, aluminum, nickel, and other conductive alloys. This model delivers efficient, solid-state welding that eliminates the need for heat, filler materials, or soldering — making it ideal for applications where conductivity, durability, and process cleanliness are top priorities.

Whether you’re welding delicate battery tabs or small copper wires, this machine delivers repeatable results with high structural strength and excellent electrical conductivity. It’s optimized for medium-duty applications and is a popular choice for industries like electric vehicle battery manufacturing, solar energy systems, wire harness production, and electronic component assembly.

With a compact footprint, digitally controlled interface, and real-time monitoring, this model is equally effective as a standalone workstation or as part of a fully automated production system. Its compatibility with PLCs, MES systems, and robotic integration makes it highly scalable and suitable for modern smart factory environments.

3000 – WAtt Ultrasonic Metal Welding Machine

Ultrasonic Metal Welding Machine

What is Ultrasonic Metal Welding?

  • Ultrasonic metal welding is a solid-state joining process that bonds two metal surfaces using high-frequency mechanical vibrations and moderate pressure.
  • No melting occurs during the process, which distinguishes it from conventional fusion welding methods like arc or resistance welding.
  • A metallurgical bond is formed by generating localized plastic deformation at the contact surfaces, resulting in a clean, strong joint.
  • The process is performed at low temperatures, which preserves the material properties of delicate metals and reduces the risk of oxidation or thermal damage.
  • It is specifically suitable for non-ferrous conductive metals such as copper, aluminum, nickel, silver, and lithium-based alloys commonly used in electronics and energy systems.
  • The welding is completed within a fraction of a second, making it highly efficient and perfect for high-speed automated production environments.
  • No need for filler materials, flux, or solder, which eliminates contamination risks and simplifies the process.
  • The equipment operates safely, producing no arcs, sparks, fumes, or hazardous byproducts — making it eco-friendly and operator-friendly.
  • It is widely adopted in high-tech industries such as electric vehicle battery assembly, solar panel manufacturing, power electronics, and wire harness production, where reliable and precise bonding is critical.
  • An ultrasonic metal welding machine is a solid-state device that bonds non-ferrous metals using high-frequency vibrations and pressure without generating heat.

Product Applications of Ultrasonic Metal Welding

  • Used for welding copper or aluminum battery tabs to busbars, ensuring strong, low-resistance joints in lithium-ion and LFP battery modules.
  • Provides reliable tab-to-tab and tab-to-terminal connections without heat damage, ideal for cylindrical, prismatic, and pouch cells.
  • Performs foil-to-tab joining in photovoltaic modules, supporting clean, lasting bonds for energy storage and solar power systems.
  • Welds delicate layers of aluminum and copper foil in solar batteries and inverters without melting, preserving conductivity and structure.
  • Fuses stranded copper wires and aluminum conductors into compact joints, eliminating the need for terminals or soldering in automotive and industrial wiring.
  • Enables terminal-free fusing of wires to reduce weight and complexity in vehicle harnesses, appliances, and smart electronics.
  • Safely joins contact pads, lead frames, and micro-connectors in printed circuit boards, offering precise welds without applying heat.
  • Ideal for compact electronics where space is limited and delicate components need high-strength bonds without soldering.
  • Used in welding foil stacks and conductive terminals for capacitors, UPS units, and power banks, ensuring consistent, high-conductivity connections.
  • Ensures durable and vibration-resistant connections in electric two-wheelers, three-wheelers, and battery swapping systems for enhanced vehicle performance.
  • Supports automated assembly of busbars and flexible copper/aluminum strips in high-voltage switchgear and industrial power distribution units.
  • Used for EV batteries, solar panels, wire harnesses, PCBs, and capacitors.

Why Use Ultrasonic Welding for Metal?

  • Ultrasonic metal welding allows two metals to be joined without generating heat through melting. This cold welding process helps preserve the physical and electrical properties of sensitive metals like copper, aluminum, and nickel, making it ideal for use in batteries, electronics, and energy systems where component integrity is critical.
  • Unlike traditional welding, ultrasonic welding does not require any consumable materials such as solder, flux, filler rods, or shielding gases. This simplifies the process, reduces operating costs, eliminates chemical waste, and makes the production line more sustainable and easier to maintain.
  • The welds created by ultrasonic metal welding machines offer excellent electrical conductivity with extremely low resistance. This makes the process perfect for applications that involve high electrical currents, such as busbar bonding in battery modules or terminal connections in power electronics.
  • The process is remarkably fast, with each weld typically completed in less than a second. This speed, combined with its ability to perform consistently, makes ultrasonic metal welding highly suitable for automated production environments that demand precision and efficiency at scale.
  • Ultrasonic welding systems allow for precise control over weld parameters such as weld time, amplitude, and force. This level of accuracy ensures each weld is consistent, meeting strict quality standards and reducing the chances of defects or rework in high-volume manufacturing.
  • The process is clean and environmentally friendly, as it does not produce harmful fumes, molten spatter, or toxic residues. This contributes to a safer working environment and reduces the need for extensive ventilation or post-processing cleanup.

Key Features and Benefits

  • Solid-State Metal Bonding: Welds without melting the materials, ensuring no heat damage or oxidation
  • Advanced Digital Generator: Features real-time auto frequency tracking for consistent performance
  • Full Amplitude Control: Digitally adjustable amplitude from 10 to 100 percent for optimal tuning
  • Multiple Welding Modes: Operates in Time, Energy, and Power modes depending on your application
  • Compact & Durable Build: Built on a rigid industrial-grade frame with a space-saving design
  • Automation Ready: Fully compatible with robotic arms, PLC controls, and conveyor-based setups
  • Real-Time Weld Quality Feedback: Built-in OK/NG feedback ensures every weld meets quality standards
  • Custom Horns & Fixtures: Titanium horns and fixtures are designed to match your exact component geometry
  • Low Maintenance, High Output: Designed for long-term reliability with minimal service interruptions

Technical Specifications of Ultrasonic Metal Welding Machine

ParameterDetails
ModelUltrasonic Metal Welding Machine – 20 kHz / 3000 Watt
Frequency20 kHz
Output Power3000 Watt
Input Voltage220V AC, 50/60 Hz
Maximum Weld AreaUp to 20 mm²
Amplitude Range10% to 100% (Digitally Controlled)
Welding ModesTime Mode, Energy Mode
User Interface4.3-inch Digital Touchscreen HMI
Cooling TypeAir-Cooled System
Operation TypeManual via Foot Pedal or Automatic Trigger
Horn MaterialTitanium Alloy (customized as per product)
Frequency TuningAuto Frequency Tracking
Fixture OptionsCustom jigs/clamps tailored to product shape
Automation CompatibilitySupports PLC, MES, and Robotic Integration
Weld FeedbackReal-time OK/NG status with weld history
Generator TypeIntelligent Digital Generator with Feedback Monitoring
Warranty (Generator)6 Months
Warranty (Transducer)3 Months
Warranty (Horn)Not Covered (Classified as a Consumable Item)

Applications of Ultrasonic Metal Welding Machine

This machine is tailored for medium-duty industrial applications requiring precise, repeatable, and high-quality metal-to-metal welding.

EV Battery Manufacturing

  • Tab-to-tab welding of aluminum and copper cells
  • Welding cell terminals to busbars in battery modules
  • Ensures strong, conductive joints without melting materials
  • Maintains the integrity of sensitive battery components
  • Enables high-throughput welding in automated lines
  • Reduces heat-affected zones and prevents oxidation

Wire Harness Production

  • Reliable joining of stranded and solid wire bundles
  • Terminal-free bonding for lightweight design needs
  • Avoids overheating or damaging insulation materials
  • Reduces contact resistance in automotive connectors
  • Ideal for fusing copper and aluminum conductors
  • Used in EVs, white goods, control panels, and sensors

PCB and Electronic Assembly

  • Precision bonding of terminals and contact pads
  • Ideal for fine wire bonding on circuit boards
  • Eliminates the need for soldering or flux
  • Maintains electrical performance without heating parts
  • Used in power banks, chargers, sensors, and micro devices
  • Reduces component stress in tight board layouts

Solar and Energy Storage

  • Welding of aluminum and copper foil interconnects
  • Tab-to-tab welding in solar battery modules
  • Suitable for thin metal layers used in PV cells
  • Minimizes thermal impact on active cell materials
  • Enhances reliability of outdoor solar installations
  • Delivers strong, corrosion-resistant connections

Capacitor and Power Bank Manufacturing

  • Welding of copper busbars and laminated foils
  • Reliable joining of thick conductor cables and tabs
  • Ideal for energy meters, capacitors, and heavy-duty panels
  • Used in switchgear, transformers, and smart grids
  • Reduces production downtime with fast cycle times
  • Ensures stable, low-resistance electrical pathways

Frequently Asked Questions (FAQ)

What types of metals can this machine weld?
It is engineered to weld non-ferrous, conductive metals such as copper, aluminum, nickel, silver, and lithium alloys. It is not suitable for welding steel or stainless steel.

Does this welding method involve heat?
No. Ultrasonic metal welding is a cold process. It uses high-frequency vibrations and pressure to form a bond without generating heat or melting the materials.

Can the machine be integrated with automation systems?
Yes. It supports PLC control, MES integration, and can be synchronized with robotic arms and conveyor systems for high-speed automation.

How durable is the ultrasonic horn?
The horn lifespan depends on material hardness and usage. On average, it can perform between 20,000 and 50,000 welds. Since it is a wear part, it is not covered under warranty.

Is training provided after purchase?
Yes. We provide on-site machine installation, hands-on operator training, and process optimization. Remote support and application guidance are also available.

What is included in the warranty?
The generator comes with a 6-month warranty. The transducer is covered for 3 months. The horn and fixtures are consumables and not included under warranty.

Why Choose Dhruv’s Ultrasonic Metal Welding Machine

  • Proven Industry Expertise: Serving battery, electronics, and energy sectors with tailored welding solutions
  • In-House Design Support: We create custom horns and fixtures to fit your specific product
  • Pan-India Presence: Fast service, spare part supply, and technical support across India
  • Automation Ready Machines: Designed for future-ready smart factory integration
  • End-to-End Application Testing: Weld validation based on your real product samples before delivery
  • Reliable Build Quality: Machines manufactured under strict quality controls and tested before dispatch

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