Custom Ultrasonic Welding Horns

Introduction

An ultrasonic welding horn, also called a sonotrode, transfers mechanical vibration from the ultrasonic stack 

to the plastic part. Its working face must suit the part geometry and provide appropriate contact during welding.

TIMEAST supplies custom horns and matching fixtures based on part drawings or samples. Material, geometry, 

operating frequency and connection details are reviewed together for the intended application.

Custom Ultrasonic Welding Horn in Operation

See a custom ultrasonic welding horn (sonotrode) in operation with its matching fixture. 

The horn geometry and fixture are tailored to the part shape, welding area and application requirements.

Need tooling for your application? Send us your part drawings or photos, plastic material, machine frequency 

and welding requirements to discuss suitable horn and fixture options.

Key Features of Ultrasonic Welding Horns 

• Precision-designed for optimal energy transfer

• Customized geometry based on product structure

• Available in titanium, aluminum, and hardened steel

• Tuned to specific ultrasonic frequencies (20kHz, 30kHz, 35kHz, etc.)

• High durability and fatigue resistance

• Consistent amplitude distribution for stable weld quality

Specifications & Customization

Matching a Sonotrode to Your Ultrasonic System

A replacement horn must match more than the nominal operating frequency. The mounting thread, 

connection surface, booster configuration and required amplitude also need to be reviewed.

For an existing machine, send us the machine model, operating frequency, booster details and photos or drawings 

of the current horn connection. If these details are unavailable, start with clear photos of the machine nameplate 

and ultrasonic stack.

For more information on horn geometry and system matching, read our guide to horn design and frequency tuning.

Materials & Manufacturing Process 

Horn material is selected according to the application, geometry, operating amplitude and production requirements.

• Titanium alloy — suitable for demanding production applications where fatigue resistance and service life justify a higher cost.

• Aluminum alloy — a widely used, cost-effective option for general-purpose applications.

• Steel — considered for applications requiring wear resistance, subject to the horn geometry and operating conditions.

Service life depends on the complete application, including loading, operating conditions and maintenance; material alone 

does not determine it.

Ultrasonic Horn Modal Analysis

Modal analysis helps assess a sonotrode’s predicted resonant frequency and vibration mode to guide design adjustments.

The manufactured horn is then checked, tuned and tested for its intended application.

Custom Horn Shapes & Matching Fixtures

Horn geometry is developed around the part surface, weld location and available machine space. 

Depending on the application, the design may use a flat or contoured working face, a block or

bar structure, or multiple working points.

The fixture is reviewed together with the horn to support and locate the part during welding. 

Final geometry depends on the part design, ultrasonic system and welding requirements.

FQA

Can you make a replacement horn for my existing machine?

We can review a replacement horn based on your machine information and existing tooling. 

Please provide the operating frequency, mounting connection details, horn photos or drawings, 

and part information. Compatibility must be checked before manufacture.

Can you design a horn if I do not have a horn drawing?

Yes. We can review the design using part drawings or samples, together with the welding requirements 

and ultrasonic system information.

Which horn material should I choose?

The choice depends on the application, horn geometry, operating conditions and budget. We can discuss 

titanium alloy, aluminum alloy and steel options after reviewing your requirements.

Do I need to provide actual samples?

Photos and drawings can support an initial review. Actual molded samples may be needed to check contact, 

fixture support and welding performance. Testing arrangements are agreed for each project.

Discuss Your Ultrasonic Horn Requirements

For a new horn or a replacement, please provide:

• Part drawings or photos showing the welding area

• Plastic material and required weld result

• Machine brand, model and operating frequency

• Booster connection details or an existing horn drawing, if available

For replacement horns, describe any cracking, marking or inconsistent welding. 

Matching frequency alone does not confirm compatibility.

Use the inquiry form below or contact us on WhatsApp: +86 159 8954 1416.