Sinceresonics is an ultrasonic horn manufacturer for 15 / 20 / 35 / 40 kHz welding systems: custom horns and sonotrodes machined in-house, replacement horns for all major machine brands, and a repair & refurbish service for worn tooling. If you need a custom ultrasonic horn that welds right the first time — or your current horn that nobody wants to rebuild — this page is for you.
What We Manufacture
| Product | Description |
|---|---|
| Custom welding horns | Slotted, stepped and exponential profiles per part drawing, any frequency |
| Sonotrodes for metal welding | Wire splice and battery tab tooling, knurled faces on request |
| Boosters | Standard ratios for all common interfaces |
| Cutting blades | Food-grade titanium blades — see the 90/255/305 mm blade guide |
| Flanged and replaceable-tip horns | For abrasive or high-wear production |
See our standard sonotrode product page: ultrasonic welding sonotrode. Components overview: ultrasonic welding components.
Horn Material Selection
| Material | Best For | Trade-offs |
|---|---|---|
| Titanium Ti-6Al-4V | High-amplitude welding, food contact, long life | Higher material cost; the default for serious production |
| Aluminum 7075 | Low-amplitude, large-area horns, prototypes | Affordable and fast to machine; softer face, shorter life |
| Hardened steel | Small horns, high wear (glass fill, degating) | Heavy, lower gain; best where wear dominates |
How We Design a Horn
A horn is a tuned resonator, not just a machined block. Our process:
- Part review — your drawing, material and weld joint define amplitude and gain
- Vibration design — gain, node position and slot layout calculated, frequency target set
- Machining — CNC on Ti-6Al-4V / 7075 / hardened steel, heat treatment where needed
- Tuning and certification — measured against the target frequency, amplitude map recorded
- Free trial welding — your samples welded with the new horn before it ships
Repair and Refurbish Service
Worn contact faces, cracked slots, drifted frequency — most horns can come back instead of going in the bin:
- Re-facing and re-knurling of weld faces
- Re-machining after slot damage, within geometry limits
- Re-tuning with a fresh frequency measurement report
- Interface repair (thread, stud, flange)
Send the old horn; we inspect, quote and refurbish. Replacement horn lines for Branson, Herrmann, Dukane, Rinco and other interfaces are standard — useful when you want one factory for tooling supply. Step-by-step changeover instructions: how to replace a sonotrode.
Lead Times and Ordering
| Item | Typical Lead Time (FOB) |
|---|---|
| Standard replacement horn (drawing on file) | 7 – 10 working days |
| Custom horn with new design | 10 – 15 working days incl. tuning |
| Refurbish service | 5 – 8 working days after inspection |
FAQ
Can you copy our existing horn without a drawing?
Yes — send the horn itself or precise measurements; we scan, model and match the interface. Frequency and amplitude are verified before shipping.
Why did our horn crack at the slot?
Usually a design or tuning issue: excessive stress concentration at slot roots, wrong material for the amplitude, or over-torque at the stud. Our designs use generous slot radii and stress-checked gain — and we tell you honestly when a proposed geometry needs changing.
Do you supply horns with our machine’s mounting interface?
Yes — common interfaces are in daily production. Tell us the machine brand and model.
Get a Horn Quotation
Send your part drawing or existing horn — you’ll get a design proposal, material recommendation and price, typically within one business day. Email jackm@mcsonic.com or call +86 189 3970 6772.