USW-800W Ultrasonic Welding Machine

Ultrasonic tab welding for low-resistance battery connections

The USW-800W Ultrasonic Battery Tab Welding Machine is a compact, lab-to-pilot scale ultrasonic metal welder designed for fast, repeatable joining of thin current collectors to metal tabs during cell assembly. Ultrasonic welding is a solid-state process: high-frequency vibration (40 kHz) is delivered through the horn under controlled force, disrupting surface oxides and creating intimate metal-to-metal bonding with minimal bulk heating. This makes it ideal for joining dissimilar and highly conductive foils where conventional thermal methods can cause damage, excessive heat input, or high contact resistance.

Key specifications & supported materials

Electrical & utilities

• Supply: 220 V / 50 Hz
• Ultrasonic power: 800 W
• Compressed air: ≥ 0.6 MPa, ~80 L/min
• Typical welding time: within 0.2 s
  
  

Battery-relevant material compatibility (single-layer tab-to-foil)

• Cathode-side: aluminium foil ~12–20 µm; aluminium tab/strip ~0.1–0.2 mm
• Anode-side: copper foil ~6–10 µm; nickel tab/strip ~0.1–0.2 mm
  
  

Welding mode (typical)

• Welding area: ~3 × 25 mm
• Configurations can support single-point or multi-point weld patterns depending on tab/foil side.
  
  

Typical applications in battery research and cell prototyping

• Tab welding during winding/stacking workflows (single-layer foils)
• R&D joining for cylindrical and small-format cells
• Low-resistance current collector connections for electrochemical testing consistency
  
  

ScienceGears supports integration with upstream/downstream battery R&D tools (electrode coating, calendaring/rolling, slitters/cutters) and test platforms (battery cyclers and electrochemical instruments) to help you build a reliable end-to-end workflow in Australia and New Zealand.