35KHz Ultrasonic Handheld Welder

Key Features

• Integrated air cooling — Air routed through the generator's rear-mounted electromagnetic valve cools the welding horn and mold, so the gun holds its set amplitude instead of drifting as it warms up.
• Real-time frequency tracking — The digital generator locks onto the 35 kHz resonance automatically and compensates amplitude as the load changes, keeping weld quality steady across a long shift.
• Amplitude control in 1% steps — Output adjusts from 10% to 100%, letting you soften the weld for thin walls and small bosses or raise it for thicker sections without changing tooling.
• Quick sonotrode change — Standard sonotrodes fit and release directly on the welding gun, so the tool can be re-tipped between jobs instead of being sent away for service.
• Built-in generator protection — Overload, voltage and transducer fault protection shuts the system down before a fault turns into a repair.
• Balanced gun, portable generator — The welding gun weighs 0.7 kg and is shaped for fatigue-free handling, while the 6 kg generator has a top-panel handle for moving between cells.

Welding Materials & Sonotrodes

Which plastics weld well

Molded thermoplastics do not all weld the same way. Amorphous plastics such as ABS, PS and PMMA normally weld at lower amplitude and shorter cycles, while semi-crystalline grades like PA, PBT and PPS ask for more energy at the joint. Tell us the exact grade and any glass or mineral filler and we will suggest the settings to start from.

Sonotrode options

Sonotrodes are available in titanium, steel or aluminum. Titanium is the usual all-round choice for plastic assembly; steel suits high-wear tips on long production runs, and aluminum suits lighter duty. As a custom ultrasonic horn manufacturer, we machine each tip to your joint geometry rather than expecting you to adapt a stock profile.

Operator Handling & Care

1. Check the air supply and cable connection before the first cycle — cooling for the horn and mold depends on clean, dry air reaching the generator's rear-mounted valve.
2. Fit and tighten the sonotrode for the job and check that it is seated square; a loose tip changes the weld and shortens tool life.
3. Run a scrap part after any change to tip, amplitude or hold time, and inspect the joint before releasing the gun to production.
4. Wipe the sonotrode face and the gun body between shifts — plastic left on the tip carries heat into the next weld.
5. Rest the gun in its stand rather than on the bench, and keep the cable clear of the work area so the connector is not strained.
6. Hold the gun steady through the cycle; the generator tracks frequency on its own, but a moving tip still leaves an uneven joint.
7. Keep a spare tip on the shelf. Tips are the wear part, and reordering from the same ultrasonic welding tooling supplier that built the machine keeps the fit and the saved settings unchanged.

Technical Support & Model Matching

Unsure which ultrasonic system fits your workpiece or production line? MCSONIC's engineering team helps you select the right machine, horn or blade configuration before you order, backed by over 15 years specializing in ultrasonic cutting and systems widely used in factories worldwide. We support customization of key parameters, integration into existing automation lines, and clear guidance on installation, commissioning and daily operation. Our after-sales engineers help troubleshoot issues remotely or on site, and selected systems support remote diagnostics. Send us your drawings, samples or cycle targets and we will recommend a practical configuration.

FAQ