Global Ultrasonic Metal Welding Machine Market 2026 by Manufacturers, Regions, Type and Application, Forecast to 2032
Description
According to our (Global Info Research) latest study, the global Ultrasonic Metal Welding Machine market size was valued at US$ 388 million in 2025 and is forecast to a readjusted size of US$ 614 million by 2032 with a CAGR of 7.1% during review period.
An ultrasonic metal welding machine applies high-frequency vibration (typically 20–40 kHz) and clamping force to create a solid-state metallurgical bond in non-ferrous metals (e.g., copper/aluminum) without melting the base material; it is widely used for wire harness terminals, connectors, and EV battery tabs/busbars, typically without solder/flux.
Upstream includes the ultrasonic generator, transducer/booster, sonotrode/anvil tooling, pneumatic/servo actuation, machine frame & safety, and in-process monitoring/data connectivity. OEMs deliver benchtop systems, gantry/cells and automation integration; recurring value often comes from tooling/consumables and after-sales service.
In 2025, global ultrasonic metal welding machine production reached approximatel 20 k units, with an average global market price is between $5k and $30k per unit.
An ultrasonic metal welding machine is a solid-state joining system that uses high-frequency mechanical vibrations and moderate clamping force to bond metal parts—typically aluminium, copper and other non-ferrous conductors—without melting them. An electrical ultrasonic generator produces high-frequency AC (usually 20–40 kHz), which is converted into mechanical vibration by a piezoelectric transducer and transmitted through a booster and horn (sonotrode) to the workpieces held against an anvil. Under pressure, the oscillating shear motion breaks up surface oxides and contaminants, promotes local plastic deformation at the interface and brings clean metal surfaces into intimate contact, forming a solid-state metallurgical bond at temperatures well below the melting point.
In terms of construction, a typical ultrasonic metal welding machine consists of a main power supply and control unit, the ultrasonic stack (transducer, booster, sonotrode), a clamping/press mechanism (often pneumatic or servo-driven), and a rigid frame or workstation. Process parameters such as vibration amplitude, welding time, clamping force and energy input are precisely controlled and recorded to ensure consistent weld quality. Compared with resistance welding or soldering, ultrasonic metal welding offers very short cycle times, low heat input, no need for filler metals or flux, and the ability to join similar or dissimilar conductive materials (e.g. copper–aluminium) with minimal distortion, making it especially attractive for battery tabs, busbars, wire harness terminations and electronic interconnects.
From an application perspective, these machines are widely used in lithium-ion battery manufacturing (tab-to-foil, foil-stack and tab-to-busbar welding), EV high-voltage cable terminations, power electronics, photovoltaic modules, automotive wire harnesses and other high-current or high-reliability connections. As pack voltages and currents rise in electric vehicles and energy-storage systems, ultrasonic metal welding machines are increasingly specified because they provide low, stable contact resistance and high mechanical integrity without thermal damage to surrounding insulation or cells.
This report is a detailed and comprehensive analysis for global Ultrasonic Metal Welding Machine market. Both quantitative and qualitative analyses are presented by manufacturers, by region & country, by Type and by Application. As the market is constantly changing, this report explores the competition, supply and demand trends, as well as key factors that contribute to its changing demands across many markets. Company profiles and product examples of selected competitors, along with market share estimates of some of the selected leaders for the year 2025, are provided.
Key Features:
Global Ultrasonic Metal Welding Machine market size and forecasts, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market size and forecasts by region and country, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market size and forecasts, by Type and by Application, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market shares of main players, shipments in revenue ($ Million), sales quantity (Unit), and ASP (K USD/Unit), 2021-2026
The Primary Objectives in This Report Are:
To determine the size of the total market opportunity of global and key countries
To assess the growth potential for Ultrasonic Metal Welding Machine
To forecast future growth in each product and end-use market
To assess competitive factors affecting the marketplace
This report profiles key players in the global Ultrasonic Metal Welding Machine market based on the following parameters - company overview, sales quantity, revenue, price, gross margin, product portfolio, geographical presence, and key developments. Key companies covered as a part of this study include Emerson (Branson), Sonics & Materials, Schunk, Telsonic, SBT Ultrasonic Technology, TECH-SONIC, Kormax System, Chuxin M&E, JD Sonic-Tech, Wuxi Hengshengte, etc.
This report also provides key insights about market drivers, restraints, opportunities, new product launches or approvals.
Market Segmentation
Ultrasonic Metal Welding Machine market is split by Type and by Application. For the period 2021-2032, the growth among segments provides accurate calculations and forecasts for consumption value by Type, and by Application in terms of volume and value. This analysis can help you expand your business by targeting qualified niche markets.
Market segment by Type
Spot Ultrasonic Metal Welder
Wire Splicing Ultrasonic Metal Welder
Seam Ultrasonic Metal Welder
Tube Sealer Ultrasonic Metal Welder
Others
Market segment by Form
Portable Type
Desktop Type
Market segment by Frequency
20 kHz
30 kHz
40 kHz
Market segment by Application
Power Batteries
Automotive Wiring Harnesses
Power Semiconductors IGBT
Others
Major players covered
Emerson (Branson)
Sonics & Materials
Schunk
Telsonic
SBT Ultrasonic Technology
TECH-SONIC
Kormax System
Chuxin M&E
JD Sonic-Tech
Wuxi Hengshengte
HYUSONIC
Market segment by region, regional analysis covers
North America (United States, Canada, and Mexico)
Europe (Germany, France, United Kingdom, Russia, Italy, and Rest of Europe)
Asia-Pacific (China, Japan, Korea, India, Southeast Asia, and Australia)
South America (Brazil, Argentina, Colombia, and Rest of South America)
Middle East & Africa (Saudi Arabia, UAE, Egypt, South Africa, and Rest of Middle East & Africa)
The content of the study subjects, includes a total of 15 chapters:
Chapter 1, to describe Ultrasonic Metal Welding Machine product scope, market overview, market estimation caveats and base year.
Chapter 2, to profile the top manufacturers of Ultrasonic Metal Welding Machine, with price, sales quantity, revenue, and global market share of Ultrasonic Metal Welding Machine from 2021 to 2026.
Chapter 3, the Ultrasonic Metal Welding Machine competitive situation, sales quantity, revenue, and global market share of top manufacturers are analyzed emphatically by landscape contrast.
Chapter 4, the Ultrasonic Metal Welding Machine breakdown data are shown at the regional level, to show the sales quantity, consumption value, and growth by regions, from 2021 to 2032.
Chapter 5 and 6, to segment the sales by Type and by Application, with sales market share and growth rate by Type, by Application, from 2021 to 2032.
Chapter 7, 8, 9, 10 and 11, to break the sales data at the country level, with sales quantity, consumption value, and market share for key countries in the world, from 2021 to 2026.and Ultrasonic Metal Welding Machine market forecast, by regions, by Type, and by Application, with sales and revenue, from 2027 to 2032.
Chapter 12, market dynamics, drivers, restraints, trends, and Porters Five Forces analysis.
Chapter 13, the key raw materials and key suppliers, and industry chain of Ultrasonic Metal Welding Machine.
Chapter 14 and 15, to describe Ultrasonic Metal Welding Machine sales channel, distributors, customers, research findings and conclusion.
An ultrasonic metal welding machine applies high-frequency vibration (typically 20–40 kHz) and clamping force to create a solid-state metallurgical bond in non-ferrous metals (e.g., copper/aluminum) without melting the base material; it is widely used for wire harness terminals, connectors, and EV battery tabs/busbars, typically without solder/flux.
Upstream includes the ultrasonic generator, transducer/booster, sonotrode/anvil tooling, pneumatic/servo actuation, machine frame & safety, and in-process monitoring/data connectivity. OEMs deliver benchtop systems, gantry/cells and automation integration; recurring value often comes from tooling/consumables and after-sales service.
In 2025, global ultrasonic metal welding machine production reached approximatel 20 k units, with an average global market price is between $5k and $30k per unit.
An ultrasonic metal welding machine is a solid-state joining system that uses high-frequency mechanical vibrations and moderate clamping force to bond metal parts—typically aluminium, copper and other non-ferrous conductors—without melting them. An electrical ultrasonic generator produces high-frequency AC (usually 20–40 kHz), which is converted into mechanical vibration by a piezoelectric transducer and transmitted through a booster and horn (sonotrode) to the workpieces held against an anvil. Under pressure, the oscillating shear motion breaks up surface oxides and contaminants, promotes local plastic deformation at the interface and brings clean metal surfaces into intimate contact, forming a solid-state metallurgical bond at temperatures well below the melting point.
In terms of construction, a typical ultrasonic metal welding machine consists of a main power supply and control unit, the ultrasonic stack (transducer, booster, sonotrode), a clamping/press mechanism (often pneumatic or servo-driven), and a rigid frame or workstation. Process parameters such as vibration amplitude, welding time, clamping force and energy input are precisely controlled and recorded to ensure consistent weld quality. Compared with resistance welding or soldering, ultrasonic metal welding offers very short cycle times, low heat input, no need for filler metals or flux, and the ability to join similar or dissimilar conductive materials (e.g. copper–aluminium) with minimal distortion, making it especially attractive for battery tabs, busbars, wire harness terminations and electronic interconnects.
From an application perspective, these machines are widely used in lithium-ion battery manufacturing (tab-to-foil, foil-stack and tab-to-busbar welding), EV high-voltage cable terminations, power electronics, photovoltaic modules, automotive wire harnesses and other high-current or high-reliability connections. As pack voltages and currents rise in electric vehicles and energy-storage systems, ultrasonic metal welding machines are increasingly specified because they provide low, stable contact resistance and high mechanical integrity without thermal damage to surrounding insulation or cells.
This report is a detailed and comprehensive analysis for global Ultrasonic Metal Welding Machine market. Both quantitative and qualitative analyses are presented by manufacturers, by region & country, by Type and by Application. As the market is constantly changing, this report explores the competition, supply and demand trends, as well as key factors that contribute to its changing demands across many markets. Company profiles and product examples of selected competitors, along with market share estimates of some of the selected leaders for the year 2025, are provided.
Key Features:
Global Ultrasonic Metal Welding Machine market size and forecasts, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market size and forecasts by region and country, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market size and forecasts, by Type and by Application, in consumption value ($ Million), sales quantity (Unit), and average selling prices (K USD/Unit), 2021-2032
Global Ultrasonic Metal Welding Machine market shares of main players, shipments in revenue ($ Million), sales quantity (Unit), and ASP (K USD/Unit), 2021-2026
The Primary Objectives in This Report Are:
To determine the size of the total market opportunity of global and key countries
To assess the growth potential for Ultrasonic Metal Welding Machine
To forecast future growth in each product and end-use market
To assess competitive factors affecting the marketplace
This report profiles key players in the global Ultrasonic Metal Welding Machine market based on the following parameters - company overview, sales quantity, revenue, price, gross margin, product portfolio, geographical presence, and key developments. Key companies covered as a part of this study include Emerson (Branson), Sonics & Materials, Schunk, Telsonic, SBT Ultrasonic Technology, TECH-SONIC, Kormax System, Chuxin M&E, JD Sonic-Tech, Wuxi Hengshengte, etc.
This report also provides key insights about market drivers, restraints, opportunities, new product launches or approvals.
Market Segmentation
Ultrasonic Metal Welding Machine market is split by Type and by Application. For the period 2021-2032, the growth among segments provides accurate calculations and forecasts for consumption value by Type, and by Application in terms of volume and value. This analysis can help you expand your business by targeting qualified niche markets.
Market segment by Type
Spot Ultrasonic Metal Welder
Wire Splicing Ultrasonic Metal Welder
Seam Ultrasonic Metal Welder
Tube Sealer Ultrasonic Metal Welder
Others
Market segment by Form
Portable Type
Desktop Type
Market segment by Frequency
20 kHz
30 kHz
40 kHz
Market segment by Application
Power Batteries
Automotive Wiring Harnesses
Power Semiconductors IGBT
Others
Major players covered
Emerson (Branson)
Sonics & Materials
Schunk
Telsonic
SBT Ultrasonic Technology
TECH-SONIC
Kormax System
Chuxin M&E
JD Sonic-Tech
Wuxi Hengshengte
HYUSONIC
Market segment by region, regional analysis covers
North America (United States, Canada, and Mexico)
Europe (Germany, France, United Kingdom, Russia, Italy, and Rest of Europe)
Asia-Pacific (China, Japan, Korea, India, Southeast Asia, and Australia)
South America (Brazil, Argentina, Colombia, and Rest of South America)
Middle East & Africa (Saudi Arabia, UAE, Egypt, South Africa, and Rest of Middle East & Africa)
The content of the study subjects, includes a total of 15 chapters:
Chapter 1, to describe Ultrasonic Metal Welding Machine product scope, market overview, market estimation caveats and base year.
Chapter 2, to profile the top manufacturers of Ultrasonic Metal Welding Machine, with price, sales quantity, revenue, and global market share of Ultrasonic Metal Welding Machine from 2021 to 2026.
Chapter 3, the Ultrasonic Metal Welding Machine competitive situation, sales quantity, revenue, and global market share of top manufacturers are analyzed emphatically by landscape contrast.
Chapter 4, the Ultrasonic Metal Welding Machine breakdown data are shown at the regional level, to show the sales quantity, consumption value, and growth by regions, from 2021 to 2032.
Chapter 5 and 6, to segment the sales by Type and by Application, with sales market share and growth rate by Type, by Application, from 2021 to 2032.
Chapter 7, 8, 9, 10 and 11, to break the sales data at the country level, with sales quantity, consumption value, and market share for key countries in the world, from 2021 to 2026.and Ultrasonic Metal Welding Machine market forecast, by regions, by Type, and by Application, with sales and revenue, from 2027 to 2032.
Chapter 12, market dynamics, drivers, restraints, trends, and Porters Five Forces analysis.
Chapter 13, the key raw materials and key suppliers, and industry chain of Ultrasonic Metal Welding Machine.
Chapter 14 and 15, to describe Ultrasonic Metal Welding Machine sales channel, distributors, customers, research findings and conclusion.
Table of Contents
116 Pages
- 1 Market Overview
- 2 Manufacturers Profiles
- 3 Competitive Environment: Ultrasonic Metal Welding Machine by Manufacturer
- 4 Consumption Analysis by Region
- 5 Market Segment by Type
- 6 Market Segment by Application
- 7 North America
- 8 Europe
- 9 Asia-Pacific
- 10 South America
- 11 Middle East & Africa
- 12 Market Dynamics
- 13 Raw Material and Industry Chain
- 14 Shipments by Distribution Channel
- 15 Research Findings and Conclusion
- 16 Appendix
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