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Ultrasonic Welding Automotive

Ultrasonic applications for automotive sector: automotive  is one of the most representative industry of the  ultrasonic welding.


In a vehicle, it is possible to find a high number of welding and riveting spots with ultrasounds.

Ultrasonic technology is applied in plastic components as well as on interior elements.


Ultrasounds in the automotive sector


This   technology can be applied in thermoplastic components as well as on internal parts made by non-woven and technical fabrics.

The ultrasonic systems manufactured by Sonic Italia are  easily integrated into automated production lines, contributing to effectively cut the production costs of the components while increasing precision and speed of the manufacturing process.


The ultrasonic sonotrodes are made of titanium, steel or Ergal, covering all frequencies and wavelengths.


The pneumatic actuators can easily fit in the production lines created by OeMs.

Normally, the thermoplastic material used in the automotive field, to manufacture bumpers or door panels are both polypropylene in its pure form or charged with a low percentage of talc.


Fixtures , composed by one full body or different ones, are studied and manufactured in Sonic Italia ’ s headquarter, after a very accurate analysis of the component to be welded and after a careful feasibility test.

The technical department studies the position of the actuators , and subsequently of the sonotrodes, depending on the given frequency and of the spaces inside the   welding system.


Sonic Italia is the trusted partner of many companies creating special lines for the automotive sectors worldwide, with its experience acquired in over thirty years of activity in the field, necessary to the development of fully automated and/or robotic solutions.


The most common applications 


Ultrasonic technology is commonly used in the following applications:



  • Welding of internal lighting components and air pipes
  • Shearing of door panels and bumpers
  • Cutting and shearing of airbags
  • Punching for parking sensors
  • Guillotine cutting, shearing and welding of seat belts

Shearing and welding on bumpers

Shearing of holes for parking sensors on the bumpers can be done on varnished bumpers because the varnish is ultrasonically led towards the inner part of the hole and it does not present any aesthetic flaw.

Multiple ultrasonic welding with antropomorphic structure

Ultrasonic welding technology is more and more installed on antropomorphic structures to be able to create multiple spots, using also different shapes of the sonotrode with the same antropomorphic structure.

Modular system 40 kHz multi-head for ultrasonic welding and tests

Sonic develops modular welding solutions in collaboration with italian and international companies manufacturing automatic machines.

Welding with full wave sonotrode 20 Khz

Sonic Italia develops and creates sonotrodes according to the application needs. The sonotrode is composed of one alluminium sonotrode and 9 titanium tips.

Automatic spot welding system

Semi-automatic workbench system for multiple spot welding on a plastic components for the automotive field.
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