Precision Engineering. Unmatched Support.
Plastics Assembly


Sonics provides design and custom machining of tooling and fixtures for ultrasonic plastic welding, vibration welding, and spin welding, as well as multi-element configurations for spot welding, staking and insertion. Tool fabrication materials include aluminum, titanium, hardened steel, stainless steel and cast polyurethanes.

Ultrasonic Horns

Ultrasonic Horns

  • Ultrasonic horns are designed with an FEA (Finite Element Analysis) simulation program that allows our engineers to observe the vibratory action of the horn prior to fabrication
  • Segmented and adjustable fixtures are built to ensure a secure fit with the molded plastic parts
  • Contoured fixtures and tools for irregularly shaped parts
  • Ultrasonic horns are inspected for even amplitude
  • For added strength and durability, carbide facing or chrome plating is applied
  • Peripheral devices to clamp, hold and align opposing parts are also available

Customers can submit application files in the following formats and media

Formats (in order of preference):

  • ProE
  • STEP
  • IGES
  • AutoCAD (DWG, DXF file formats)


  • Email (Please ZIP any files larger than 10 meg)
  • Sonics FTP Site (Please contact Sonics for upload permissions and instructions)
  • CD-ROM / DVD / flash drive
  • File sharing services