Ultrasonic welders for plastic

What is an ultrasonic welder?

Sonomax ultrasonic welding machines represent the technological heart of the entire range of ultrasonic joining systems for thermoplastic materials. Each welding machine is designed and built in Italy, with mechanical, electronic and acoustic components of the highest quality, to guarantee precision, reliability and long life even in the most demanding industrial environments.

How ultrasonic welding works

Ultrasonic technology makes it possible to permanently join two or more plastic parts by means of high-frequency mechanical vibrations, without the use of glues, solvents or external heat. The energy generated is transmitted to the joint between the parts by a dedicated sonotrode, causing controlled melting of the material.

Available types of welding machines

Sonomax offers a complete range of welding machines for machining:

• Manuals
• Semiautomatics
• Automated or in-line integrated

Advantages over other joining methods

• Very fast welding cycles
• No preheating
• Strong, aesthetic, repeatable joints
• No consumables or chemicals
• Maximum energy efficiency
• Easy integration on robot islands or automatic lines

Compatible materials

Sonomax welders successfully work on a wide variety of thermoplastic polymers, including:

• Polypropylene (PP)
• Polyethylene (PE)
• Acrylonitrile butadiene styrene (ABS)
• Polycarbonate (PC)
• Nylon (PA)
• Polystyrene (PS)
• PMMA and composite technopolymers

Each machine is designed to optimise output on the specific material, thanks to a customisable combination of frequency, power, pressure and cycle time.

Fields of application

• Automotive (headlights, dashboards, tanks, connectors)
• Home appliances (filters, panels, controls)
• Electronics (housings, circuits, sensors)
• Packaging (blisters, capsules, capsules)
• Medical (masks, containers, PPE)
• Technical textiles (TNT, felt, multilayer)
• Renewable energies (inverters, photovoltaic components)
• Toys, furniture, sporting goods

Customised and Made in Italy solutions

Each welding machine is designed by the Sonomax team based on customer specifications: type of material, part geometry, production cycle, integration requirements. Our technical department is able to develop customised solutions and provide a testing and rapid prototyping service.

Integration with Industry 4.0 and 5.0

All welders can be prepared for Industry 4.0 and 5.0, with remote control, data collection, IoT interface and predictive diagnostics.

Reliability and after-sales service

Sonomax welding machines are successfully installed in hundreds of plants in Europe and around the world, in industries where reliability is an absolute requirement. Our after-sales service guarantees technical support, spare parts, training and updates even years after delivery.