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Ultrasonic sonotrode

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ultrasonic full wave sonotrode for TPU welding

ultrasonic full wave sonotrode for TPU welding

SONIC ITALIA SRL

Viale de Gasperi, 76
20017 RHO (MI) Italia

CONTACT FORM

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Ultrasonic sonotrodes manufactured by Sonic Italia.

The primary function of the sonotrode is to transmit sound energy (mechanical vibrations) produced by the converter, to the workpiece.
It transfers the vibrations  to the plastic component. 

If needed, it is possible to install a booster on the vibrating group, in order to increase the amplitude of the ultrasonic waves. To do this efficiently, the ultrasonic sonotrode needs to have a specific profile to the component geometry. There are two basic horn shapes: circular and rectangular.

 

  • Circular sonotrode may be solid or hollow, and have flat, tapped or contoured faces.
  • Rectangular sonotrode may incorporate reliefs for part projections, and may also be contoured faced.

 

Composite sonotrode

 

Composite sonotrodes are half-wave sonotrodes coupled together. Each horn is individually tuned, and one or more tips is then coupled to a “mother” sonotrode.
They are normally used in applications with a large surface area or for applications requiring multiple stacking, multiple insertions and multiple welding points.

 

Manufacturing sonotrodes

 

Sonic Italia internally manufactures sonotrodes using five axes CNC milling machine and F.E.A. software “Finite Element Method” assuring quality and stability for every kind of shape. 
Sonic Italia produces sonotrodes from 20 kHz up to 70 kHz.

 

Sonotrodes: materials

 

Because of the high stresse a sonotrode is subjected to, it needs to be made of materials that have high strength and good acoustic properties (transmitting the ultrasonic energy efficiently).

  • Steel alloy sonotrodes are among the lowest strength horns. D2 Steel alloys are normally used (e.g. Bohler grades KNL 105 & 110).
  • Aluminium alloy sonotrodes are stronger. Grades 2024, 6061 and 7075 are popularly used. T6 annealing is recommended.
  • Titanium alloy sonotrodes are the strongest. Grades 6-4 and 7-4 are normally used for ultrasonic applications.

 

Thanks to the great strenght/price ratio, aluminium is the mainly used material.
It can be chrome or nickel plated, anodised or even carbide faced, if desired, to minimise wear when welding glass filled plastics.

 

If you have additional questions about our ultrasonic sonotrode, please contact us. We will be more than happy to answer any questions you may have. You can also learn more by browsing our site, where you will find a presentation of our product range and research. Fill out the contact form


 


Nonwovens ultrasonic welding
Ultrasonic welding solutions for welding non-woven fabrics. Materials can be 100% acrylics or blends.

Plastic assembly systems
Ultrasonic plastic assembly is used when  high aesthetic quality and high production speed are required.

Ultrasonic bonding
Customized ultrasonic bonding solutions for synthetic fabrics and non-wovens.

Ultrasonic cutting
Sonic Italia manufactures up to date machines for ultrasonic cutting of thermoplastic materials.

Ultrasonic food cutting
Ultrasonic blades suitable for almost all kind of food cutting with different frequencies.


Ultrasonic sealing
Ultrasonic technology generates the heat for a friction process and for sealing process from within the plastic film.

Ultrasonic sewing machine
The ultrasonic process is versatile - you can seam, cut, slit, trim, tack, emboss, or cut and seal simultaneously. 

Ultrasonic slicer
Ultrasonic cutting systems integrated in automatic or semi automatic slicers.

Ultrasonic slitting
Ultrasonic slitting is the most efficient solution for a clean cut which prevents unraveling.

Ultrasonic tools
Ultrasonic tools for customised solutions for cutting and welding.

Ultrasonic welding
Sonic Italia produces ultrasonic machines for welding thermoplastics, which can be applied in several industries.

Hand-held Ultrasonic Welder
Manual ultrasonic cutting and welding solution for manual cutting and spot welding.

Manure Belt Welder
Discover more about our manual ultrasonic welder designed for manure and egg conveyor belts.


Ultrasonic cutting sealing films fabrics
Ultrasonic sealing of films and fabrics: applications in clothing industry, non-woven, packaging and textile.

Ultrasonic Insertion
Ultrasonic insertion of a threaded brass rivet  in a plastic component.

Ultrasonic blades
Sonic Italia internally produces the ultrasonic blades with different shapes and designs.


Ultrasonic Linear Circular Weaving Cutter
Ultrasonic linear and weaving cutter. Ideal for manufacturing rafia products.

Ultrasonic Punching
Ultrasonic punching solutions for plastic, acrylics and filtration fabrics.

Ultrasonic Rotative Bonding System For Pleated Filters
The rotary bonding system designed for pleated filters is "green" because it does not require the use of solvents or adhesives.

Ultrasonic Sonotrode
Ultrasonic sontorodes: thirty years' experience in manufacturing customized sonotrode.

Ultrasonic Spot Welding
Ultrasonic spot welding is possible both in automations and manually.

Ultrasonic Stud Welding
Ultrasonic Stud Welding is the suggested option when similar plastics parts need to be welded at single or multiple localised points.
 

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