Everything customers ask us most — about choosing a machine, tooling, applications, ordering and after-sales support. Can’t find your answer here? Send us your question — our engineers reply within one working day.
Choosing the Right Machine
How do I choose between 15kHz, 20kHz and 35/40kHz?
Match frequency to part size and joint position: 15kHz for large or thick parts and far-field joints, 20kHz as the general-purpose choice for most plastic assemblies, and 35–40kHz for small, delicate or electronic components. Read our full guide: 15kHz vs 20kHz vs 40kHz.
Pneumatic, servo or handheld — which machine type fits my production?
Pneumatic machines (iAG, iBA series) suit stable, repetitive production with simple control. Servo-driven machines (iSF, iSTW, iSFT) add precise depth, speed and force control for demanding or cosmetic welds. Handheld spot welders (GSH) are for large parts, tack welding or low-volume work. Many customers use both: servo for the main process, handheld for spot checks.
Can one machine run more than one frequency?
Only with a multi-frequency platform where the whole stack — generator, converter, booster and horn — is designed for each frequency. Our iSFT series supports multiple frequencies on one platform. You cannot run a 40kHz horn on a 20kHz generator.
I don’t know which machine I need. Can you help?
Yes — that is the most common conversation we have. Send your part drawings, material and production target, and our engineers will recommend the machine, frequency, power and tooling. We can also run tests on your samples before you commit to anything.
Applications & Technical Questions
Which materials can be ultrasonically welded?
Most thermoplastics — ABS, PC, PS, PMMA, POM, PA, PP and blends — with amorphous materials being the easiest and semi-crystalline (PP, PA, POM) needing more energy. Ultrasonic metal welding covers copper, aluminum and their alloys, including multilayer battery tabs and wire harnesses.
Can ultrasonic welding join different materials?
Dissimilar thermoplastics generally cannot be welded directly; ultrasonic staking or insertion is the usual solution for joining plastic to metal or to a non-weldable plastic.
What is near-field vs far-field welding?
Near-field means the joint is within about 6 mm of where the horn touches the part; far-field means more than 6 mm. Far-field joints need lower frequency (15 or 20kHz) so vibration survives the distance. Avoid designs where the joint sits about a quarter wavelength away — amplitude drops close to zero there.
My parts won’t weld properly. What should I check first?
In order: amplitude and pressure settings, energy director or joint design, fixture support (no gaps under the part), horn contact position and wear. Our pre-operation debugging checklist covers the sequence: Ultrasonic Plastic Welder Debugging Guide.
How do I weld large parts that a normal horn can’t cover?
Three options: a slotted bar horn (up to and beyond ~110 mm at 15kHz), multiple horns on a multi-head machine, or spot/scanning welding where the part or horn moves. Tell us the weld area and we will recommend the most practical route.
What about cycle time?
Plastic welding cycles typically run 0.3–2 seconds depending on material and part size; our 15kHz large-part machines support up to 5s weld time for thick sections. Ultrasonic metal tab welding can reach about 0.2 seconds per spot on servo systems with automatic frequency tracking.
Tooling, Horns & Spare Parts
Do I need a custom horn (sonotrode) for my part?
In most cases yes — the horn face must match your part geometry and joint. We design and machine custom horns in titanium and aluminum from your 3D file or sample, and tune them to your machine’s frequency.
How long does custom tooling take?
Tooling lead time depends on complexity and current production load. Send your drawing and we will confirm the schedule together with the quotation.
How often should horns be replaced or reconditioned?
Wear depends on material, amplitude and volume. Watch for falling weld quality, visible face wear, cracks or frequency drift — a horn that no longer tunes properly usually needs reconditioning or replacement. We also supply generators, transducers and horns as matched systems.
Are spare parts available long-term?
Yes. We keep service parts for our machine series and can supply transducers, generators, cables, pneumatic components and horns after delivery.
Ordering, Shipping & Payment
What is the minimum order quantity?
MOQ depends on the model and configuration — single machines are welcome for evaluation and trial production. Volume projects are quoted with dedicated pricing. The safest path: tell us your annual volume and we will structure the offer around it.
How do I get a quotation?
Use the quote button on any product page or contact us with your part, material, target output and any drawings. Quotations typically include machine configuration, tooling and delivery terms.
Do you provide samples or welding trials?
Yes. Send your parts or material samples and we will weld them and return a test report with the parameters that worked. This is the fastest way to confirm a machine choice before ordering.
What are the payment terms?
We work with standard international terms (T/T, and L/C for larger orders). Exact terms are agreed with the quotation.
How are machines shipped and installed?
Machines ship in export-grade cases with the documentation you need for customs clearance. We provide installation guidance, parameter setup and operator training — on site or remotely, depending on destination and project size.
Do your machines meet CE or other certifications?
Machine certification requirements depend on your market and model. Tell us your destination country and required documents, and we will confirm what is available for the configuration you choose.
Service & Support
What warranty do you provide?
All machines carry a manufacturer warranty, with the exact terms stated in your quotation and order confirmation. Consumable tooling (horns) is covered against manufacturing defects.
How fast is support when something goes wrong?
Send us the symptom, plus photos or a short video of the machine and generator display. Most issues — tuning, alarms, parameter problems — are resolved remotely within a working day. Spare parts and engineer visits are arranged based on your location.
Do you train our operators?
Yes. We provide operator and maintenance training covering parameter setup, tooling changes, daily checks and troubleshooting — remotely or at your site.
Can you support legacy or third-party machines?
We support our own series fully. For third-party machines we can often supply compatible horns, transducers and generators — send details and photos and we will confirm fit.
Still have a question? Contact our engineering team — we answer technical questions even if you are not ready to buy.