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Falcon-20, -35 & -40  and the NEW VIPER-20 & -35
Ultrasonic Spot Welder Systems

Tech-Sonic’s spot welder systems deliver strong metallurgic welds that are high in conductivity and used for a variety of electronics, from delicate, small-gauge parts to heavy-duty applications.

This welding system has been the workhorse in lithium ion and lithium polymer battery manufacturing the past eight years, capable of welding up to 80 layers of copper or aluminum foil. It is also often used in the automotive and electrical industries as well as the solar industry to complete photovoltaic-cell and DC-power connections.

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With all the advantages of ultrasonic welding, these Falcon spot welders bond nonferrous metals, such as copper, aluminum, nickel, brass, gold and silver. The bonds created are typically stronger than soldered- or resistance-welded joints, and they eliminate weld oxidation.

Ultrasonic welding lowers production cost and is environmentally friendly because there's no need for consumables, such as solder, flux and crimps, and there's a low energy requirement.

The Falcon and Viper spot welder systems offer these benefits:

• Vertical motion for extreme accuracy
• Solid tooling design for consistent welding and long tool life (no tip required)
• Consistent, quality welds with exceptionally fast cycle times
• Ergonomic benchtop design that's easy to use
• Competitive initial cost and low cost for replacement tooling
• Uniform weld quality guaranteed through integrated constant welding parameters
• Easy to operate. Training done on-site within a day
• Easy set up, maintenance and operation
• Can be custom automated

Falcon-20

The Falcon-20 delivers 20 kHz frequency and is designed for heavy-duty applications. With 3.0 kW maximum power output, a maximum of 16 amperes, it weighs 30 kg / 66 pounds.

This welder is the core technology for Tech-Sonic's automated Ring Termination Machine and the semi-automated Armature Welding Machine.

Download PDF Specification Sheet; See Video in New Window

Falcon-35

The precise welding capability of this 35-kHz welding system creates superior bonds between delicate, medium-sized metal parts. It has 1.2 kW maximum power output, a maximum of 10 amperes, and weighs 18 kg / 39.6 pounds.

Falcon-20 and -35 generator offers:

• Integrated quality control system with automatic process monitoring ensures seals within preset quality parameters of weld energy, time and height
• Automatic calibration and frequency tuning adjustment
• Adjustable tolerance
• Electronic pressure regulator
• Digital amplitude control for precise setting (+/- one micron)
• Automatically adjusts energy
• RS232 port for optional programmable logic controller (PLC)
• Stores nine weld programs
• Password-protected system for high-level security

Download PDF Specification Sheet; See Video in New Window

Falcon-40

This ultrasonic spot welding machine creates high quality bonds between delicate, small gauge parts via 40 kHz. With 700 W maximum power output, a maximum of 10 amperes, it weighs 18 kg / 39.6 pounds.

Falcon-40 generator offers:

• Integrated quality control system with automatic process monitoring ensures seals within preset quality parameters of weld energy and time
• Manual calibration
• Automatic frequency tuning adjustment
• Analog pressure regulator
• RS232 port for optional programmable logic controller (PLC)

Download PDF specification sheet; See Video in New Window

Sample Welds

Just provide the metal components for your application. We’ll weld them in our test lab and suggest the ultrasonic application that best meets your needs. Request for Welding Test.

Specifications are believed to be accurate and provided as information only. However, no responsibility is assumed by Tech-Sonic Inc. for their use.