Ultrasonic Welder

About Ultrasonic Welders

Applications

8,000W Series

5,000W Series

3,000W Series

Compact Units

Ultrasonic Cutter

Custom Equipment

Induction Heaters

About Ultrasonic Welders

High quality Ultrasonic Welding Supplies and Accessories
Lower prices on equipment and electrodes than other manufacturers
Shorter lead time, especially on electrodes
Free test welds and unparalleled customer support

How We Can Help You

Advanced Integrated Technologies ( AIT ) is a welding equipment and technical support provider for Nippon Avionics ( Avio ) brand of ultrasonic welders and accessories. We can evaluate your product samples, provide free test welds, and accurately specify which equipment is best for your application. We can then provide the equipment you need at an economical price, and assist with any technical issues you encounter setting up your welding process. Submit a contact form or call us today to request assistance with your next project.

Introduction to Ultrasonic Welding

Principles of Ultrasonic Metal Joining

Unlike resistance welding, ultrasonic welder horn oscillator vibration removes oxide film on the metal surface and scatters surface layer impurities in order to create a state of solid-phase welding by bonding metal atoms.

Advantages MetalWelder-3

•Reduces damage and provides efficient energy use because of low welding temperatures (less than approx. 50% of the melting point)

•Suitable for connection of thin metal foil such as aluminum foil or thin copper foil. Also suitable for connection of copper wires.

•Reduces electrical resistance and provides joints with good electrical conductivity

•No special surface treatment required

•No consumables such as solder are required. Eco-Friendly while reducing costs

•Space-saving, easy to introduce automation

•Permits dissimilar metal joints, e.g., joining aluminum to copper

AVIO Ultrasonic Welders

•Ultrasonic Welders use Ultrasonic Energy to perform various bonding & cutting functions such as resin welding, resin seat cutting, resin cutting, and metal joining. The basic components of Ultrasonic Welding Systems consist of an Ultrasonic Oscillator Unit and a Welder Main Unit (Press).

•Products offered include a wide range of output models from a compact 40W unit to the world’s highest in class 8,000W unit to meet customer needs.

These products are manufactured by Nippon Future Co. Ltd. (a wholly-owned subsidiary of Nippon Avionics Co., Ltd.).

Features of Ultrasonic Welding

• Fast welding - For most applications, welding times are short allowing increased production

• Stable production - Setting conditions may be stored for future use ensuring consistent welds among

production cycles

• Quiet performance - Non-audible frequency range is used for most products

• Air-tight seals – Selecting proper horns for each product accomplishes an air-tight weld

• Environmentally friendly - No adhesive chemicals are used during the manufacturing process that

compromise security and recyclability

• Saves money - Shorter weld times significantly reduces manufacturing cost

Wide Selection of Ultrasonic Horns

Ultrasonic horns incorporate a half-wavelength resonator cavity which efficiently transmits vibration energy. Horn materials include aluminum alloy, titanium alloy, and die steel depending on the welding purpose.

We offer horns that best suit your particular work. We also design and manufacture clamping jigs.

Applications

Applications of Ultrasonic Welding

Examples of Ultrasonically Welded Parts

welder-products

8,000W Series

Maximum Output 8,000W – World's Highest Performance in Its Class!

Includes Color LCD Display and Simple-to-Use Touch Panel

W5000-Series

W5000 series ultrasonic plastic welders allow control of welding parameters (welding time, welding displacement, welding energy, & welding data output). A color LCD touch screen front panel provides user friendly and intuitive operation.

Welding parameter data used for controlling can be output to a network environment (LAN) or saved to a USB storage device during operation. This easily accessed parameter data history is valuable for quality control.

Color LCD display of main weld parameter waveforms is beneficial for better on-site management and analysis of the welding process.

Wide Range of Welding Management Functions

•Welding energy control and management – Maintains welding energy constant and monitors the upper and lower limits of the weld head displacement

•Welding process control and management - Holds and monitors the melting depth (DEPTH) and finished dimensions（HEIGHT)

•Management and recording of set up & welding data – Records and timestamps each welding parameter. Supports USB storage devices and connection to a network environment (LAN).

•Control and manage welding time - Delay, Oscillation period, Retention time (cooling time)

•Display of power - Displays the peak power reached during welding

•Display and record welding waveform - Frequency, air pressure, applied current, displacement of welding head, actual applied pressure and energy can be displayed and recorded

•Other Functions

• Spherical seat parallelism adjustment

• Frequency check

• 2-step pressure

• After burst

• Load cell pressure measurement and management

• 1 μm resolution welding management

• Electro-pneumatic regulator pressure control

5,000W Series

Ultrasonic Welder W5000 Series - Large Type

• A rigid press structure for welding large items

• Provides welds using super-sized horns

W5000 Series Ultrasonic Welders
	W5040	W5050	W5070	W5080	W5085	W5095	W5155	W5185
Output Power	1200W	1600W	2000W	2400W	2400W	3000W	5000W	8000W
Frequency	20kHz				15kHz
Power Source	3Φ AC200 V ± 5% 50/60Hz
Oscillation Method	Frequency Automatic Tracking System (ATHMOS)
Oscillator
Adjustment	Variable (0-100%, 1% step)
Soft Start	Variable (40-200ms)
Operation Type	Color LCD Touch Panel
Welding Management System	Timer/Depth/Height/Energy mode,Waveform parameter display, Welding condition data recording (USB memory, LAN environment connection)
Dimension WxDxH (mm)	295x550x200		325x580x200					325x580x385
Weight	~10kg		~13kg				~16kg	~30kg
Main Unit of Welder
Pressure Method	Air Cylinder (Electro-Pneumatic Regulator and Load Cell Equipped)
Minimum Pressure	120N		170N
Maximum Pressure	1500N		2500N				5000N	7000N
Welding Control Method	Linear Scale (0.001 mm res)
Parallelism Adjustment	Spherical Seat-Style Support Flange
Compressed Air Supply Required	Clean Air (0.06-0.5 MPa)
Head Stroke	315mm						Custom-designed
Horn Stroke	70mm (dia. 63mm Air Cylinder		95mm (dia. 80mm Air Cylinder				Custom-Designed
Dimension WxDxH (mm)	320x550x1215		380x610x1335				Custom-Designed
Weight	~52kg		~88kg				Custom-Designed

3,000W Series

Basic Desktop Model of Ultrasonic Plastic Welder with Small-Footprint

Operation / setup iseasy. Changing horn height will not change the oscillator timing as the weld head is equipped with a pressure trigger. No adjustment required.

Standard equipment on this product includes: Frequency Monitor, Amplitude Adjustment mechanism and an External Ultrasonic Output

Oscillator Panel

Easy-to-see display of 12-step power switching.
Work piece stresses are reduced by adjusting oscillator startingpoint (Adjustable soft-start)
Oscillator amplitude is continuously variable between 0-100% toeasily select the optimum weld condition.

Automatic Welding Process Controller

•Vibrator has a casing

•Horn spherical seat leveling adjustment function is also available.

Ultrasonic Welder W3000 Series - Large Type

• A rigid press structure for welding large items

• Provides wide area welds using super-sized horns

W3000 Series Ultrasonic Welders
	W3040	W3050	W3070	W3080	W3085	W3095	W3155	W3185
Output Power	1200W	1600W	2000W	2400W	2400W	3000W	5000W	8000W
Frequency	20kHz				15kHz
Power Source	3Φ AC200 V ± 5% 50/60Hz
Oscillation Method	Frequency Automatic Tracking System (ATHMOS)
Oscillator
Amplitude Adjustment	Variable (0-100%, 1% step)
Soft Start	Variable (40-200ms)
Dimension WxDxH (mm)	295x500x180		325x500x180					325x500x385
Weight	~10kg		~12kg				~15kg	~30kg
Main Unit of Welder
Pressure Method	Air Cylinder
Minimum Pressure	120N		170N
Maximum Pressure	1500N		2500N				5000N	7000N
Parallelism	Spherical Seat-Style Support Flange
Compressed Air Supply Required	Clean Air (0.06-0.5 MPa)
Head Stroke	315mm						Custom-Designed
Horn Stroke	70mm (dia. 63mm Air Cylinder)		95mm (dia. 80mm Air Cylinder)				Custom-Designed
Dimension WxDxH (mm)	320x550x1215		380x610x1335				Custom-Designed
Weight	~52kg		~88kg				Custom-Designed

Compact Units

Ultrasonic Hand Welder W2005-28/40

Hand-held 250W ultrasonic welder•Wide range of applications from prototype to mass production

Ultrasonic Spot Welder W1002-60

Compact and lightweight ultrasonic spot welder
Ideal for basting before sewing, small boss ratio caulking, and riveting.

Ultrasonic Small Welder Models W3011 - W3015

Compact ultrasonic welder 500W - 800W
Units for automation are also available.

Ultrasonic Vibrator Unit

Serves a wide range of applications when used in automation.

Compact Welder Series
	W2005	W1002	W3011	W3012	W3013	W3014	W3015
Output Power	250W	40W	500W		800W	500W
Frequency	28kHz. 40kHz	60kHz	20kHz, 27kHz, 28kHz, 39kHz, 50kHz		27kHz, 39KHz	20kHz, 27kHz, 28kHz, 39kHz, 50kHz
Power Source	AC100V+/- 5% 50/60 Hz					1 Φ AC200 V	AC100V+/- 5% 50/60 Hz
Oscillator
Amplitude Adjustment	0-100% with External Variable Transformer		0-100% with External Variable Transformer	50-100% (5 Steps)	0-100% with External Variable Transformer	0-100%(Continuously)
Dimensions WxDxH (mm)	164x242x105	123x170x88	254x365x146			254x415x146
Weight	~2kg	~1kg	~6kg			~7kg
Main Unit of Welder
Pressure Method	Hand Held		Air Cylinder
Maximum Pressure	100N (10kgf)		250N
Compressed Air Supply	-	-	Clean Air (0.06-0.5 MPa)
Horn Stroke	-	-	75mm (dia. 25mm Air Cylinder)
Dimension	dia.36-52 x 275mm	dia. 31x159mm	320x380x710
Weight	~450g	~200g	~30kg

Ultrasonic Cutter

Ultrasonic Cutter W1003-40

Compact hand-held type ultrasonic cutter.
Permits cutting of paper and resin, and "gate cutting".

Food Cutter

Cleanly cut various confections such as cakes, sponge cakes, pies, candies, and various food types including vegetables, meat and fish.
Solves unsightly appearance problems
Eliminates dependence on skilled workers.

		W1003
Output Power		40W
Frequency		40kHz
Power Source		AC100V+/- 5% 50/60 Hz
Oscillator
Dimension WxDxH (mm)		39x200x186
Weight		~1kg
Main Unit of Welder
Maximum Pressure		50N (5kgf)
Dimension		dia.24x200mm
Weight		Approx.200g

Custom Equipment

Ultrasonic Clear File Welder

(Ultrasonic Direct Welding)

Welder with Stand

Soundproofing Unit

Simple Press Unit for HandyWelder

Multi-Type Ultrasonic Welder for Long Objects

(Ultrasonic Direct Welding)

Multi-head Ultrasonic Welder

（Ultrasonic Transmit Welding

On Demand Sealer

(Ultrasonic Seam Welding)

Mesh Ultrasonic Melt Cutting Equipment

(Ultrasonic Melt Cutting)

Multi-point Fusing Equipment for Automobiles

(Ultrasonic Boss Fusing)

XYZ-Direct Robot-type Caulking Equipment (Ultrasonic Fusing /Insert)

Bolt Nut Insert Equipment

(High-frequency Induction Heating

Induction Heaters

High-frequency Induction Heating Equipment

Metal Materials such as Screws or Nuts are easily Inserted into Molded Plastic Components!

Induction heating units incorporate high frequency generators for non-contact heating of metal using electromagnetic induction.

Induction heated metal screws and nuts can be easily and securely inserted into molded plastic components.

Unlike heater-method equipment, induction heating quickly heats both magnetic and non-magnetic materials. No pre-heating is required which contributes to reduced power consumption and prevents deterioration of metal parts.

Various Induction Coils

We offer a wide variety of coils to suit your applications.

Induction Insert samples