An ultrasonic wire harness welding machine joins stranded copper or aluminum wires with a cold, solid-state weld — no solder, no crimp barrel, no heat damage to insulation. Sinceresonics builds wire harness welders and wire splicers for automotive, EV battery and industrial harness production. This page covers capabilities, splice quality, machine selection and price.
Why Ultrasonic for Wire Splices
- True metallurgical bond. High-frequency vibration removes oxides and forges the strands into a solid cross-section — the weld is the conductor, not a crimp pressing metal against metal.
- Lower electrical resistance. A typical ultrasonic splice measures lower and more stable resistance than a crimp of the same gauge, which matters for current-carrying harnesses and EV battery circuits.
- No consumables. No sleeves, solder or filler — the splice cost is machine time only.
- Insulation-friendly. The joint stays cool; strip lengths stay short, saving wire on every splice.
Splice Capabilities
| Parameter | Specification |
|---|---|
| Weldable cross-section | 0.5 – 60 mm² (single or bundled strands) |
| Wire material | Copper (bare, tinned, enameled), aluminum, nickel, brass |
| Frequency | 20 kHz standard; other frequencies on request |
| Weld power | Up to 8,000 W depending on splice size |
| Energy / time / depth control | All three modes, with quality monitoring |
| Typical cycle time | 0.5 – 1.5 s per splice including clamp |
Our production machine for this application is the conductor ultrasonic wire harness welder; for aluminum and non-ferrous conductors see the non-ferrous metal welding machine.
Ultrasonic Splicing vs Crimping vs Soldering
| Method | Resistance | Consumables | Strain on conductor | Traceability |
|---|---|---|---|---|
| Ultrasonic splice | Lowest, stable | None | Minimal (cold process) | Energy/depth log per splice |
| Crimp | Good, varies with tooling | Sleeve per splice | Cold work on strands | Crimp force monitor |
| Solder | Low but brittle joints | Solder, flux | Heat annealing | Process-dependent |
Ultrasonic Wire Welding Machine Price
Pricing is quoted per configuration: the splice cross-section range, wire materials, quality-monitoring outputs and tooling set all decide the final number. Most harness houses start with one machine plus interchangeable anvils and sonotrodes — see custom horn manufacturing. Send your splice spec and you’ll have a quotation within one business day — trial welding is free.
Related Applications
- Battery tab welding — foil-to-tab joints for EV cells and modules
- Ultrasonic tube sealing — sealing metal tubes with ultrasonic power
- Quality standards: read our metal welding standard overview for battery tab welding
FAQ
Can one machine splice different wire gauges?
Yes — the machine stays, the anvil and sonotrode insert change per cross-section range. Most lines keep two or three insert sets.
Does it work with enameled (magnet) wire?
Yes. Ultrasonic welding breaks through the enamel at the joint, which is one of its main advantages over soldering enameled strands.
What quality data can we log?
Weld energy, power curve, time and depth per splice, available over I/O or fieldbus for traceability systems.
Send Us Your Splice Spec
Tell us your wire cross-sections, strand counts and target resistance — we’ll return a machine configuration and a free trial-weld report. Email jackm@mcsonic.com or call +86 189 3970 6772. See also the ultrasonic metal welder range.