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Ultrasonic welding

Join plastic in a fifth
of a second.

Presses, hand welders, spin and metal welding systems — with the joint design, materials and troubleshooting knowledge that decides whether any of it works.

Start a welding enquiry Call 1300 647 664

Misonics ultrasonic welding presses — an MS 750 and two MS 3000 bench presses

A Misonics MS 3000 ultrasonic welding press with tooling set in the fixture

MS 3000, set up for a job. The fixture holds the part, the horn comes down onto it, and the same settings run again tomorrow. Tooling is made to the part — it is not something you buy off a shelf.

The presses

Bench presses you can run from day one

Every press on this page is the same machine underneath — a generator, a converter, a booster and a horn, driven down onto a part held in a fixture. What changes up the range is the force available, the stroke, and how tightly the weld is controlled.

The touchscreen sets amplitude, pressure and time, stores the settings per part, and logs what each weld actually did. That log is what gets you through an audit.

See the presses →Generators and sonotrodes →

A Misonics MS 3000 welding head on a six-station rotary indexing table with a pneumatic feed arm, guarding and a PLC panel

Automation

The same head, on a dial

This is an MS 3000 — the same press from the bench — sitting over a rotary indexing table. Six fixtures on the dial, a pneumatic arm that feeds the part in, guarding around the work, and the generator in the cabinet underneath.

The operator loads one station while the head welds another, so the weld time stops being the bottleneck. A PLC screen sits beside the welder control: the welder owns amplitude, pressure and time, the PLC owns the index, the feed and the interlocks.

What gets engineered to the job is the dial, the fixtures and the handling. The welding head does not change.

Talk to us about a cell →The presses →

What it is

Joining plastic without glue, screws or heat

Ultrasonic welding converts mains electricity into high-frequency mechanical vibration, drives it through one part into the joint, and uses the friction at that interface to melt and fuse the material. The weld takes a fraction of a second, adds no consumable, and leaves a joint as strong as the parent material when the joint is designed properly.

1GeneratorConverts 50 Hz mains to 20, 35 or 36 kHz electrical energy

2ConverterPiezoelectric stack turns that into mechanical vibration

3BoosterScales the amplitude up or down to suit the material

4SonotrodeCustom horn that couples the energy into your part

5FixtureHolds and supports the part so the energy goes to the joint

Four of those five are catalogue items. The fifth — the sonotrode — is made for your part, and it is the one that decides whether the process works. That is why a welding enquiry starts with the part, not the machine.

Why people move to it

Six reasons it replaces what you do now

No consumable

No adhesive, no solvent, no screws, no inserts. The cost per joint after the tooling is electricity.

Fractions of a second

Typical weld times are 0.2 to 1.0 seconds. Cycle time is usually set by handling, not by the weld.

Hermetic when you need it

The right joint design gives a genuine airtight, watertight seal — which adhesive rarely does repeatably.

Repeatable and measurable

Weld by time, energy, distance or absolute distance, with the result recorded per cycle. That is a process you can validate.

Clean

No fumes, no VOCs, no cure time, no shelf life. Matters in medical, food and electronics.

Scales

The same process runs on a bench press for prototypes and in a fully automated line at millions of parts a year.

The range

Machines, components and the process behind them

A Misonics MS 750 ultrasonic welding bench press with a touchscreen control head

5 press families · 500 W – 4.5 kW

Ultrasonic presses

Bench and floor-standing presses from a 54 mm hand-held head to a 6,000 N floor press. Time, energy, distance and absolute-distance weld control.

UHG · MS 450 to MS 6000

See the models →

A Misonics hand-held ultrasonic welding gun on its lead, plugged into an HGS 3510 generator

500 – 1500 W · 20/35/36 kHz

Hand welders & spot guns

Portable welding, riveting, staking and spot welding where the part cannot come to a press — large assemblies, trim, and repair work.

Hand-held · gun format

See the range →

A Misonics spin welder — an MS 3000 head in a guarded cell with a touchscreen, light guards and a foot pedal

100 – 4000 rpm · to ø300 mm

Spin welding

Friction welding for circular joints — filter bowls, caps, reservoirs and any round part where a continuous hermetic seal is needed.

Servo · 1 to 5 kW

See the system →

A Misonics ultrasonic metal welder with its generator cabinet and foot pedal

Non-ferrous · solid state

Metal welding

Copper and aluminium joined without heat or current — wire splices, terminals, battery tabs, busbars and tube sealing.

Splicers · spot · rotary

See the range →

A Misonics HGS 3510 ultrasonic generator — keypad, colour display and USB port

500 W – 5 kW · 20/35/36 kHz

Generators, converters & sonotrodes

The stack on its own — generators, converters, boosters and custom sonotrodes to retrofit or rebuild an existing machine.

Modular, upgradable

See components →

Six industries

Applications

What actually gets welded: automotive, medical, packaging, electronics, textiles and appliances — and which process suits each.

Where it is used

See applications →

Before you buy anything

Three guides worth reading first

Most failed ultrasonic welding projects fail in the part design, not the machine. These three cover what decides success before a purchase order exists.

Cross-section of a weld joint before and after: a triangular energy director 0.3 to 0.7 mm tall melts and fills the joint

Design guide

Joint design & energy directors

Get this right and the weld is easy. Energy director dimensions, shear joints, near-field vs far-field, and the mistakes that cannot be fixed on the machine.

With dimensions

Read the guide →

Amorphous polymers soften over a temperature range; semi-crystalline polymers hold solid then melt sharply

Weldability

Which plastics weld, and which fight you

Amorphous against semi-crystalline, filler and regrind limits, moisture, mould release, and why you generally cannot weld two different resins.

Material guide

Read the guide →

The diagnostic order: what changed, horn healthy, part dry, fixture solid, then settings

Diagnostics

Troubleshooting welds that will not hold

Flash, marking, weak welds, diaphragming, damaged internals and inconsistent results — causes and what to change.

Fault guide

Read the guide →

Watch it work

Welding on video

Spin welding a 65 mm part

The part sits in a nest cut for it, the head comes down and runs against the fixed half, and the machine stops it within ±0.1°. Filmed on our welding partner’s floor.

Spin welding →

How we work on welding. Misonics is your Australian point of contact. Machines, tooling and application engineering come from our welding partner, who has run thousands of standard and custom applications — so your parts are assessed by people who weld for a living, and the quotation comes back engineered rather than estimated. You deal with us; the application work happens behind that.

Practically, that means the enquiry form asks for more than most. Resin and grade, wall thickness, joint type, what the weld has to achieve, volumes — and photos or drawings of both halves. Send that and the first reply is useful. Send “how much is a welder” and it will not be.

Start a welding enquiry Read the FAQ

What are you welding?

Ultrasonic welding is decided by the parts — the resin, the wall, the joint and what the weld has to do. Send photos and drawings through the enquiry form and you get an engineered answer.

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