USW-Ultrasonic Spot Welder

Ultrasonic Spot Welder for Battery Tab and Electrode Welding

The Ultrasonic Spot Welder is designed for precision joining of battery tabs and stacked electrode sheets used in lithium-ion cell research, pilot-scale development, and pre-production assembly. It uses high-frequency mechanical vibration to create a solid-state weld at the interface of conductive materials. This process breaks surface oxides, promotes intimate metal-to-metal contact, and forms a localised bond without the need for filler material or excessive bulk heating.

Working Principle and Key Features

Operating at ultrasonic frequency with CPU-based control, this system is well suited to joining thin copper and aluminium foils to tabs in pouch cell fabrication workflows. A touch-based control interface supports repeatable parameter setting for welding time, pressure, and energy delivery, helping researchers optimise weld quality across different electrode stacks.

Key features include

• Ultrasonic welding for stacked copper and aluminium electrode sheets
• Suitable for lithium battery tab welding in R&D and production environments
• Typical power configuration around 2600 W, with higher-power configurations available for more demanding weld stacks
• Standard operating frequency of 24 kHz
• Customisable welding point sizes such as 4 × 6 mm, 4 × 8 mm, 4 × 10 mm, and 4 × 12 mm
• CPU control for stable, repeatable welding behaviour
• Compressed air operation with typical requirement of at least 0.5 MPa
  
  

Compatibility and Applications

This instrument is suitable for welding multilayer copper foil with nickel or nickel-clad copper tabs, and multilayer aluminium foil with aluminium tabs. It is commonly used in lithium-ion pouch cell assembly, electrode stacking workflows, tab connection studies, battery prototyping, and materials research laboratories.

For laboratories building a complete battery development workflow, this welder integrates well with related ScienceGears solutions such as electrode coaters, die cutters, vacuum sealing systems, battery cyclers, and electrochemical testing platforms. Choosing ScienceGears gives Australian and New Zealand researchers access to application-focused support, system matching guidance, and practical integration across the broader battery research instrument stack.