Dhruvs Ultrasonics

20Khz, 3000 to 120000w
Ultrasonic Metal welding is used in the automotive and electronics industries to produce batteries, cable connections, etc. In metal welding, metals are welded in high temperatures, for instance. We differentiate between metal active gas (MAG) and metal inert gas (MIG) welding. Active gases form a connection with the metal, inert gases do not.
Ultrasonic welding, on the other hand, uses ultrasonic waves to join the metals. The ultrasonic welding of metals is a cold welding process, as barely any heat is generated apart from at the weld spot. At this point, high-frequency sound waves are introduced to the parts being welded. Precise tools make it possible to retain a consistent quality during each weld process, and to have reproducible results each time.

20 kHz 5000 Watt Ultrasonic Metal Welding Machine | High-Power, Precision Welding for Industrial Use
Boost your manufacturing performance with the 20 kHz 5000 Watt Ultrasonic Metal Welding Machine—designed for high-strength, reliable metal bonding in demanding industrial environments. This powerful ultrasonic welder is ideal for medium- to large-scale applications across sectors such as EV battery production, electronics, aerospace, and automotive manufacturing.
Key Features:

Robust 5000W Ultrasonic Power: Provides stable, high-energy output for fast and reliable metal welding, even in thicker or multi-layered materials.

20 kHz Welding Frequency: Ensures deep, high-integrity welds with minimal thermal stress and excellent joint quality.

Intelligent Digital Control System: Features automatic frequency tracking, real-time monitoring, and programmable settings for process consistency.

Durable Titanium Horn and Fixtures: Engineered for long-term use with minimal wear under high-frequency operations.

User-Friendly Operation: Touchscreen interface allows for easy control, setup, and real-time diagnostics.

Applications:

EV battery module and pack welding

Copper and aluminum busbar joining

Battery tab and terminal welding

Wire harness and connector bonding

Heat sink and conductive foil welding

Why Choose This 5000W Ultrasonic Welder?
Combining advanced technology with a powerful 5000W output, this ultrasonic metal welder offers the perfect solution for manufacturers needing speed, accuracy, and reliability. It delivers consistent results with minimal maintenance and integrates easily into semi- or fully-automated production lines.
Maximize productivity and weld quality with the power of ultrasonic technology—order your 5000W machine today!

In the rapidly evolving landscape of Electric Vehicles (EVs), Power Electronics, and Green Energy, the integrity of electrical connections is paramount. Dhruvs Ultrasonics introduces its state-of-the-art Ultrasonic Metal Welding (UMW) Machine, engineered specifically for high-conductivity bonding of Copper Busbars and Thimbles.

Unlike traditional soldering or resistance welding, our ultrasonic technology creates a solid-state metallurgical bond that ensures maximum conductivity, zero oxidation, and unmatched durability.

By utilizing high-frequency mechanical vibrations, the machine disperses surface oxides and contaminants, creating a pure molecular bond between the copper busbar and the thimble. This results in a weld area with the lowest possible electrical resistance.

Equipped with an intelligent touchscreen interface, the machine allows for precise control over welding parameters including Energy, Time, and Amplitude. This ensures consistent results across thousands of cycles.

Since the process does not reach the melting point of copper, there is no thermal deformation, no hardening of the material, and no need for cooling cycles. This preserves the mechanical properties of the copper.

• No Consumables: Eliminates the need for solder, flux, or shielding gases.

• Low Energy Consumption: Uses significantly less power compared to traditional resistance welding.

• Environmentally Clean: No fumes, sparks, or hazardous waste.

Our horns and anvils are crafted from high-grade tool steel with specialized heat treatments, ensuring a long life span even when working with the high-clamping pressures required for thick copper busbars.

• EV Battery Packs: Bonding copper tabs to busbars for high-current discharge.

• Power Distribution: Attaching heavy-duty thimbles to copper plates in switchgears.

• Automotive Wiring: Termination of thick-gauge cables into copper connectors.

• Solar Industry: Interconnecting busbars in PV modules and inverters.

At Dhruvs Ultrasonics, we understand that every busbar geometry is different. We offer:

• Custom Tooling Design: We design sonotrodes specifically for your thimble shape.

• Application Lab Testing: Send us your samples, and we will provide a comprehensive weld strength report.

• Robust After-Sales Support: Rapid response for maintenance and spare parts across India.

Upgrade your production line with the precision of Dhruvs Ultrasonics.

Contacts us today for a live demonstration or a quote.

Introducing the latest innovation in metal joining technology, the Ultrasonic Metal Welding Machine. This advanced welding system uses high-frequency ultrasonic vibrations to create strong, precise, and reliable bonds between metal components without needing additional materials or excessive heat. Ideal for a wide range of industries, this machine offers unparalleled efficiency and performance for various metal welding applications.

• High-Frequency Ultrasonic Vibrations: Uses ultrasonic waves at frequencies typically between 20 kHz to 40 kHz to produce frictional heat, resulting in a solid-state weld.
• Non-Destructive Joining: Ensures high-quality welds without melting the base materials, maintaining the integrity and strength of the metals.
• Precision Welding: Capable of welding small, delicate components with high precision, making it suitable for micro-welding applications.
• Quick and Efficient: Significantly reduces welding times compared to traditional methods, enhancing productivity and reducing operational costs.
• Eco-Friendly Operation: Eliminates the need for fluxes, fillers, or other consumables, resulting in a cleaner, greener welding process.
• Robust and Durable: Constructed with high-quality materials to withstand demanding industrial environments and ensure long-lasting performance.

• Automotive Industry: Ideal for welding electrical connections, battery tabs, and aluminium or copper components.
• Electronics: Perfect for assembling circuit boards, connectors, and other electronic components requiring precise and reliable welds.
• Medical Devices: Used in the manufacture of medical equipment where clean and strong joints are critical.
• Aerospace: Suitable for bonding lightweight and dissimilar metals in aircraft components and other aerospace applications.
• Energy Sector: Utilised in the production of solar panels, fuel cells, and other energy-related components.

• Ultrasonic Generator: Converts electrical energy into high-frequency ultrasonic vibrations.
• Transducer: Converts electrical signals into mechanical vibrations, delivering them to the weld area.
• Sonotrode (Horn): Transfers the ultrasonic energy to the materials being welded, often custom-designed for specific applications.
• Anvil: Supports the materials during welding, ensuring proper alignment and pressure.
• Control Panel: User-friendly interface for adjusting parameters, monitoring the welding process, and ensuring precise control over welding operations.
• Safety Features: Includes protective enclosures, emergency stop buttons, and interlock systems to ensure operator safety.

• Advanced Technology: Utilising the latest in ultrasonic welding technology to provide superior weld quality and reliability.
• Versatility: Capable of handling a wide range of materials and thicknesses, making it suitable for diverse industrial applications.
• User-Friendly: Intuitive control panel and software for easy operation, minimising the learning curve and maximising productivity.
• Cost-Effective: Reduces production costs by minimising energy consumption, eliminating consumables, and enhancing production speed.
• Reliable Support: Backed by comprehensive customer support and service, ensuring your machine operates at peak performance.

Ultrasonic Metal Welding Machine is an advanced and efficient solution for joining non-ferrous metals without the need for additional materials like adhesives or solder. Utilizing high-frequency ultrasonic vibrations, this machine creates strong, durable bonds by applying pressure to the materials and fusing them at the molecular level.
Designed for precision and consistency, it is ideal for applications in industries like electronics, automotive, medical devices, and energy storage. The machine features a user-friendly interface for easy operation, customizable welding parameters, and advanced safety mechanisms to ensure reliable performance. Its compact and robust design makes it suitable for high-volume production, delivering superior weld quality with minimal energy consumption. Perfect for delicate and intricate components, the Ultrasonic Metal Welding Machine provides a fast, eco-friendly, and cost-effective alternative to traditional welding methods.

Ultrasonic Metal Welding Machine offers a reliable, environmentally friendly, and cost-effective solution for high-quality, non-destructive metal joining.

Ultrasonic welding technology bonds multiple wires together or wire to any other metal parts by applying the energy of high frequency vibrations to the product or parts to be welded together.

Ultrasonic metal welding is a process of joining two metal parts by applying ultrasonic vibration in a shear (scrubbing) mode. The ultrasonic vibration displaces the surface oxides and contaminates at the interfaces of the two parts, thereby allowing intimate metal-to-metal contact from which the weld occurs

High-Performance 20 kHz 7000 Watt Ultrasonic Metal Welding Machine | Precision & Power for Industrial Applications

Upgrade your production line with the advanced 20 kHz 7000 Watt Ultrasonic Metal Welding Machine—engineered for high-efficiency and precision bonding of metal components. Designed for industries such as automotive, electronics, battery manufacturing, and aerospace, this ultrasonic welder delivers exceptional performance for welding copper, aluminum, and other conductive metals.

Key Features:

• Powerful 7000W Output: Provides consistent, high-energy ultrasonic waves for fast, reliable metal welding.

• 20 kHz Frequency: Optimized for deep penetration and strong welds without damaging delicate components.

• Digital Control System: Ensures precise tuning, real-time monitoring, and automated adjustment for repeatable results.

• Durable Titanium Horn & Tooling: Designed for long-lasting, high-frequency operation with minimal wear.

• User-Friendly Interface: Touchscreen control panel with customizable settings and diagnostic features.

• Environmentally Friendly Process: No need for flux, solder, or external heat—clean and energy-efficient.

Applications:

• Lithium-ion battery tab welding

• EV battery module assembly

• Copper and aluminum foil welding

• Wire harness and cable termination

• Heat exchanger and HVAC component joining

20 kHz 3000 Watt Ultrasonic Metal Welding Machine | Precision Welding for Industrial Metal Applications
Enhance your production efficiency with the 20 kHz 3000 Watt Ultrasonic Metal Welding Machine, purpose-built for precision bonding of non-ferrous metals such as copper and aluminum. Ideal for medium- to high-volume manufacturing, this ultrasonic welder is perfect for applications in electronics, automotive, battery assembly, and aerospace industries.
Key Features:

3000W High-Efficiency Power Output: Delivers stable ultrasonic energy for strong, consistent welds with minimal thermal distortion.

20 kHz Ultrasonic Frequency: Offers deep penetration and precise bonding for thin and thick metal layers alike.

Advanced Digital Control System: Enables real-time process monitoring, adjustable parameters, and automatic tuning for reliable operation.

Rugged Titanium Welding Horn: Built for high-frequency durability, ensuring long service life and reduced maintenance.

Intuitive User Interface: Touchscreen control panel allows easy operation, parameter setting, and quick diagnostics.

Applications:

Lithium battery tab and busbar welding

Copper and aluminum foil welding

Wire and terminal bonding

PCB and sensor connections

Automotive electrical component assembly

Why Choose This Ultrasonic Welder?
This 3000W ultrasonic metal welding machine offers the perfect balance of power, precision, and cost-efficiency. With its 20 kHz frequency and state-of-the-art control system, it ensures high weld integrity, low defect rates, and smooth integration into automated production lines.
Invest in next-generation ultrasonic welding technology—order now for enhanced production quality and speed!

High-Performance 20 kHz 7000 Watt Ultrasonic Metal Welding Machine | Precision & Power for Industrial Applications
Upgrade your production line with the advanced 20 kHz 7000 Watt Ultrasonic Metal Welding Machine—engineered for high-efficiency and precision bonding of metal components. Designed for industries such as automotive, electronics, battery manufacturing, and aerospace, this ultrasonic welder delivers exceptional performance for welding copper, aluminum, and other conductive metals.
Key Features:

Powerful 7000W Output: Provides consistent, high-energy ultrasonic waves for fast, reliable metal welding.

20 kHz Frequency: Optimized for deep penetration and strong welds without damaging delicate components.

Digital Control System: Ensures precise tuning, real-time monitoring, and automated adjustment for repeatable results.

Durable Titanium Horn & Tooling: Designed for long-lasting, high-frequency operation with minimal wear.

User-Friendly Interface: Touchscreen control panel with customizable settings and diagnostic features.

Environmentally Friendly Process: No need for flux, solder, or external heat—clean and energy-efficient.

Applications:

Lithium-ion battery tab welding

EV battery module assembly

Copper and aluminum foil welding

Wire harness and cable termination

Heat exchanger and HVAC component joining

Why Choose Our Ultrasonic Metal Welder?
With a robust 7000W power rating and 20 kHz frequency, this machine offers unmatched strength and stability for high-volume metal welding operations. Reduce cycle times, improve bond integrity, and increase productivity with minimal operator training required.
Order now and transform your manufacturing efficiency with cutting-edge ultrasonic metal welding technology!