In modern busbar manufacturing, the connection of copper and aluminum has long been standard. However, the implementation is technically demanding and in many manufacturing processes leads to rejects and unreliable connections that lose quality over time. Ultrasonic welding offers a particularly process-stable, material-friendly and economical alternative that has proven itself in numerous industrial applications.
In busbar manufacturing, developers are faced with a central challenge: creating connections that are both highly electrically conductive and extremely resilient mechanically — permanently, reproducibly and in short cycle times. Ultrasonic welding can solve this challenges.
Efficient joining technologies play a central role in the modern manufacturing of busbars. Especially in the manufacture of busbars, which are used in power distribution systems, electric vehicles and other high-current-carrying applications, choosing the right joining technology is crucial for product quality, production efficiency and cost structure.
The benefits of ultrasonic welding for membranes used in filtration and venting
Ultrasonic welding has established itself as a proven process for integrating membranes into applications with pressure equalisation or filtration functions. Shorter process times and clean, reproducible results make this joining technology particularly attractive for automated production systems where the focus is on increasing output and efficiency.
How ultrasonic bonding makes hygiene products more eco-friendly
Legal requirements and changing consumer behavior make sustainable production methods in diaper manufacturing a necessity. At the same time, companies are under pressure to optimize their costs and remain competitive. Ultrasonic welding offers an innovative solution that combines ecological and economic advantages.
Manufacturing adhesive-free hygiene products with ultrasonics
Manufacturers of hygiene products such as diapers are constantly under pressure to reduce costs while delivering high-quality products. One effective long-term method of meeting these requirements is to use ultrasonic bonding instead of conventional adhesives. This efficient joining method offers significant advantages in terms of cost savings, efficiency, and sustainability.
How ultrasonics optimizes the manufacturing of hygiene products
Diapers are an indispensable companion for babies or adults with incontinence problems. In addition to key aspects such as absorbency and leak protection, wear comfort is becoming increasingly important when selecting the right diaper. Consumers are paying more and more attention to products that feel soft on the skin and are comfortable to wear.
The softness of nonwoven materials plays a decisive role here. But how can the softness of the nonwoven material be preserved during the manufacturing of diapers and other hygiene products? Choosing the right bonding process is a key factor.
Herrmann is thrilled to announce the grand opening of its newest Tech Center and laboratory in Monterrey, Mexico, on April 24, 2025. With over 60 years of pioneering German-designed ultrasonic technologies, this milestone marks a significant step in bringing the latest innovations closer to manufacturers and industry leaders in Mexico and beyond.
Automated connection of medical components for maximum output
Perfect for automated assembly: Thanks to minimized welding times and real-time process control, ultrasonics is ideal for manufacturing medical components in high volumes. Find out the advantages of the technology for your application in this article.
Joining Plastics of Medical Devices Without Adhesive
Particularly for medical products with direct skin contact, high wear comfort and skin compatibility are crucial for the quality of the product and customer satisfaction. Manufacturers should therefore avoid chemicals such as IBOA and connect plastics with processes that do not require adhesives, solvents or environmentally harmful substances - ultrasonics make this possible.
The switch from PVC to thermoplastic elastomers (TPE) in medical technology promotes health and environmental protection. TPE is phthalate-free, biocompatible and easier to recycle, which reduces the risks of allergies and environmental pollution. Despite challenges in joining TPE, ultrasonic welding offers an effective solution for stable and durable joints. This step improves product quality and minimizes health risks in the medical industry.
Minimal scrap rates with twice as fast cycle times: New developments in ultrasonic welding enable an optimization of production and can permanently reduce manufacturing costs for batteries and wire harnesses. A big help comes from the experience gained in the welding of plastics.
Increasing the sustainability of EV with ultrasonics
Sustainability becomes particularly interesting for companies when combined with cost savings. However, is that possible in the production of electric vehicles? As a particularly efficient, safe, and material-friendly process, ultrasonic welding offers some exciting options.
Utilizing the digital potential of battery manufacturing
Up to 150 data points per welding process: Ultrasonic welding offers exciting opportunities for the digitalization of battery production - both in manual workstations and automated systems. If the data is used correctly, both safety and efficiency can be permanently increased, and new standards can be set in quality control.
Unlocking the potential of Digitalization with ultrasonic welding
The most valuable resources in manufacturing are no longer materials or machines. It is the data. Whether in automated systems or at manual workstations: Every welding process of battery cells or wire terminal applications offers the opportunity to collect valuable digital information.
Joining medical applications quickly and sustainably with ultrasonics
Connecting plastics without adhesives: Using ultrasonics as a joining technology, companies can produce their applications skin-friendly and eco-friendly. If certain specifications for the components are met, the process can also be used for sensitive applications with complex geometries.
Herrmann Ultraschall is supporting a social welfare center with 10,000 euros. The money will urgently purchase essential all-weather jackets for approximately 100 caregivers, an expense that could not be covered by the original budget.
Faster wire-terminal connections with large cross-sections: with the Ultrasonic Power Stack 12.000, Herrmann Ultraschall has developed an expansion for the ULTRASAFE W that increases the machine's power while simultaneously reducing cycle times. This increases the manufacturing’s efficiency and makes the user-friendly welding machine even more versatile.
Another 10,000 euros for the protection of the oceans: After 2022, Herrmann Ultraschall is once again supporting the non-profit organization The Ocean Cleanup, which frees the oceans from plastic waste.
New process: Sealing uncoated paper with ultrasonics
Ultrasonic sealing of uncoated paper is a joining process that is as innovative as it is environmentally friendly, enabling packaging companies to save significant amounts of energy and resources. Patent holder Syntegon Technology GmbH recently handed over exclusive rights to the process to Herrmann Ultraschall. The company wants to move the process to market maturity and establish it in the packaging industry.
With the SLIMLINE systems, Herrmann Ultraschall offers the ideal welding solution for the automation of production processes. In addition to increased cycle rates, companies benefit from consulting with Herrmann Engineering, which enables rapid integration into production lines.
Ultrasonic welding is one of the easiest ways to increase efficiency and sustainability in your manufacturing. Thermoplastic materials as well as non-ferrous metals can be joined together safely, quickly and permanently with the help of ultrasonic vibrations. In this article, you will learn about the advantages of welding with ultrasonics and discover the possibilities of this modern joining technology.
In a new feasibility study, Herrmann Ultraschall investigated the welding of a recycled plastic. The result: with the right parameters, comparable welding results are as achievable as with conventional plastics.
With the common goal of safe and sustainable battery production, Herrmann is optimizing the ultrasonic welding process of battery cells together with CUSTOMCELLS. Initial results of the partnership show an opportunity for significant savings in terms of energy and rejects.
Herrmann Ultraschall is expanding its management team with André Deponte as the new Chief Sales Officer. With digital processes and an even closer cooperation between the global sales teams, he wants to create a consistent, exciting customer experience worldwide.
Having the chance to be involved in the development of an ultrasonic welding machine: for Norbert Ennemoser from Ultra Reflex GmbH, Germany, this wish has come true. He was able to put the new HiQ machine generation from Herrmann Ultraschall through its paces for eight weeks as part of a field test. A collaboration that generated a lot of excitement on both sides.
