SpliceRite™ Ultrasonic Wire Welder and Splicer

The SpliceRite™ ultrasonic wire welder creates high-strength, solid-state wire splices with ultra-low electrical resistance—without melting wires, producing sparks or causing arc damage. Designed for demanding automotive, aerospace, electronics and industrial applications, this wire splicers produce strong, consistent and clean electrical connections quickly and reliably.

Using Sonobond’s exclusive Wedge-Reed system, the SpliceRite ultrasonic wire welder combines high vibratory force with low-amplitude coupling to weld tinned and oxidized wires in a single pulse without pre-cleaning. This capability helps manufacturers create reliable wire splices while reducing preparation and processing steps. No other ultrasonic welders have this capability.

How Does an Ultrasonic Wire Welder Work?

An ultrasonic wire welder uses high-frequency mechanical vibrations and pressure to create a solid-state metallurgical bond between nonferrous wires. Unlike fusion welding, ultrasonic wire welding does not melt the base metals. The system applies low-amplitude, high-force shear-mode vibration parallel to the welding surface. The line of force is positioned directly over the weld area, helping eliminate bending stress and create strong, durable wire connections.

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Dual Head SpliceRite™ Wire Welder

This system maximizes ultrasonic wire welding effectiveness by combining low vibratory amplitude with high vibratory force. Its shear-mode ultrasonic vibration runs parallel to the welding surface for dependable, repeatable bonding. Positioning the line of force directly over the welding surface helps eliminate bending stress associated with other ultrasonic metal welding methods and achieving more durable welds than crimp or solder methods. The solid-state process eliminates the porosity and intermetallic compounds that can occur with fusion welding.

What Is an Ultrasonic Wire Welder Used For?

Ultrasonic wire welders are used to create reliable electrical connections where low resistance, high strength and repeatability are important. SpliceRite is designed for demanding wire-splicing applications in industries including:

• Automotive
• Aerospace
• Electronics
• Industrial manufacturing

Applications can include joining wire bundles and creating electrical connections from tinned or oxidized nonferrous wires without pre-cleaning.

Why Use an Ultrasonic Wire Splicer?

Compared with processes that melt the base metals, ultrasonic wire splicing creates solid-state metallurgical bonds without arcs, sparks or fumes. SpliceRite can also weld tinned and oxidized wires without pre-cleaning, helping manufacturers reduce processing steps while creating strong, low-resistance electrical connections.