Sonotrodes, boosters and transducers for ultrasonic welding

Made in our machine shop. Customisable in aluminium, titanium and steel

In the field of ultrasonic welding of thermoplastic materialskey components that guarantee the efficiency and precision of the process are the sonotrodes, i booster and the piezoelectric transducers. These three elements form the heart of the acoustic system and determine the quality of the final weld. Sonomax Srl, with over twenty years' experience in the sector, designs and manufactures these components in-house, using the highest quality materials and advanced simulation tools.

What they are and how they work

The piezoelectric transducer is the starting point of the system. It receives theelectricity from the generator and converts it to mechanical vibration energy high frequency, exploiting the piezoelectric effect of special ceramic materials. This vibration is then transmitted to the boosterwhich acts as a mechanical amplifier, increasing or decreasing the vibration amplitude according to application requirements.

The sonotrode is the final element of the system, responsible for transmitting the ultrasonic energy to the workpiece. It must be designed with extreme precision, as its shape, material and resonance frequency directly influence the quality of the welded joint.

Sonomax's role in design and production

At the Sonomax machine shop, all components are made in-houseguaranteeing maximum quality control. Thanks to theFinite Element Analysis (FEA)each sonotrode is optimised to achieve the best combination of acoustic properties e mechanical resistance.

Sonomax offers:

Standard sonotrodes in aluminium, steel and titanium (20, 30, 35 and 40 kHz)
Booster with various amplification ratios and materials (aluminium, titanium)
Piezoelectric transducers 400 to 3000W, calibrated to specific frequencies

You can design customised sonotrodesfrom 2D and 3D technical drawings of the part provided by the customer or from sample geometries.

Types and materials

I sonotrodes can be:

Step
Catenoidal
Exponentials
Rectangular o bar
Circulars (solid or hollow)
With threaded tips o compounds

In addition to classic aluminium and titanium, specific surface treatments (e.g. tungsten carbide, Tefloning and others) to improve durability and cleanliness during welding.

I boosteracoustically calibrated, allow a mechanical amplitude adjustmentessential for consistent and reliable welds. They can amplify or reduce vibration depending on material sensitivity or joint geometry.

I piezoelectric transducersavailable in various frequencies (20-30-35-40 kHz), are manufactured with selected ceramic components and tested during assembly to ensure frequency stability e optimal energy yield.

Advantages of ultrasound technology

Compared to other thermoplastic joining methods (adhesives, screws, hot welding), the ultrasound system with sonotrode/booster/transducer offers:

Speed of execution
Absence of consumables
High repeatability e aesthetic quality of the joint
Automation possibilities consistently
No release of fumes or solvents

Industrial applications

These components are used in numerous industrial sectors:

Automotive: welding of headlights, dashboards, electronic housings
Medical: manufacture of filters, valves, sterile containers
Packaging: closing blisters, tubes, food trays
Technical textiles: threadless stitching, PPE
Electronicsassembly of sensors, housings, micro-components

Sonomax ensures compatibility with most generators on the market, also offering complete solutions with generators and welders.

Technical Requirements

For an efficient system, it must be guaranteed:

Compatible frequencies (20-40 kHz depending on application)
Adequate power (250-2500 W)
Calibration of the mechanical-acoustic system
Choice of sonotrode material depending on the piece to be welded

How Sonomax responds to the market

Sonomax is capable of:

Provide customised sonotrodes for complex geometries
Offer technical support and design consultancy
Execute vibration test e acoustic tuning internal
Ensuring fast production times and spare parts in stock

The approach is oriented towards maximum industrial reliabilitywith a focus on material traceability and compliance with required standards.

Frequently asked questions (FAQ)

What data are needed to design a customised sonotrode?

You need the working frequency, the geometry of the workpiece, the materials involved and the welding conditions.

Are Sonomax components compatible with other brands?

Yes, we can make sonotrodes, boosters and transducers compatible with existing systems.

How do you guarantee the repeatability of welds?

Through acoustic and impedance calibration, frequency control and certified materials.

How often should a sonotrode be replaced?

It depends on the intensity of use, the material of the sonotrode and that of the welded workpiece.

What happens if the sonotrode goes out of resonance?

It can cause weak soldering or damage other acoustic components: it must be replaced or re-frequency tuned.

Find out more

For more information, visit the pages dedicated to:
Ultrasonic welders,
Actuators,
Generators,
Ultrasonic technology.