Leverage the world’s most advanced ultrasonic welding expertise, systems, and solutions
Ultrasonic welding is a quick, clean, and highly controllable joining process. By applying high-frequency ultrasonic vibrations under controlled pressure, materials are bonded without the need for adhesives, fasteners, or excessive heat. AIR provides top-tier ultrasonic welding expertise, proprietary technology, and services across various industries, including automotive, aerospace, electronics, and medical devices. Our systems are engineered to seamlessly transition from development to full-scale production, ensuring reliable weld quality in complex automated manufacturing settings.
Capabilities
Complete ultrasonic welding solutions
AIR has been designing and building industry-leading custom ultrasonic welding equipment for decades. Our engineers offer expertise in joint design, process development, and custom ultrasonic horn design to many industries that require plastic welding and hermetic sealing.
- In-house horn design and testing
- Compact designs allowing for greater horn density
- Capability to weld by power, energy, or time with one controller
- Frequency tracking and auto-tuning capabilities
- Direct integration for weld-by-distance applications
- Data tracking with full track-and-trace capabilities
- Complete in-house warranty, service, and support with AIR360
- End-to-end ultrasonic welding solutions, with the expertise, equipment, and support to maximize your throughput and quality while minimizing your downtime and total cost of ownership.
- Proprietary, patented end-of-arm tooling, the AIR Sonics 2.0, increases work density, improves quality, reduces initial investment, and delivers over the long term.
- Ultrasonic welding of thermoplastic and precision-engineered components
- Integration of ultrasonic welding into automated and semi-automated systems
- Systems designed to meet repeatability, quality, and validation requirements
- Scalable platforms suitable for low- to high-volume production
- Expertise in stand-alone and complete assembly systems
- Enabling Industry 4.0 control and diagnostic elements
- Advanced servo-controlled actuation and force control for consistent energy delivery
- Process monitoring, data capture, and traceability
Approach
Development of your ideal ultrasonic welding solution begins with an exploratory conversation
Our multisector, multiproduct, cross-functional expertise, combined with close customer collaborations, delivers world-class ultrasonic welding systems. We provide top-tier ultrasonic welding expertise, proprietary technology, and excellent service. Our approach includes:
- Quick turnaround on cutting-edge ultrasonic welding systems, service, and parts, enabled by deep expertise, proprietary ultrasonic technology, and our extensive in-house inventory
- Extensive remote diagnostics and support for fast assessments, adjustments, and fixes
- Open, agile, early-stage ultrasonic welding explorations
- Detailed examinations of all relevant downstream and upstream processes
- Assembly of the best-fit, cross-functional ultrasonic welding AIR team for the project
- Delivery of an initial ultrasonic welding proof-of-concept when required
- Building and maintaining close, open, collaborative relationships throughout
Impact
Advancing our customers’ welding precision and speed
AIR’s ultrasonic welding systems deliver immediate and long-term operational wins, including:
- Clean, energy-efficient joining without consumables
- Consistent, high-integrity welds at high production speeds
- Improved process control and quality assurance
- Reduced scrap, rework, and process variability
- Scalable solutions that support future automated production requirements
- Long-term, reliable performance
- Low total cost of ownership
- Industry 4.0 control
Case studies
The CTO of a large thin film solar manufacturer wanted to reduce the cost of a critical electrical component by a factor of 10. The company lacked time and internal resources to validate and implement…