Global Ultrasonic Metal Welding Machine Market Growth 2026-2032
Description
The global Ultrasonic Metal Welding Machine market size is predicted to grow from US$ 369 million in 2025 to US$ 598 million in 2032; it is expected to grow at a CAGR of 7.5% from 2026 to 2032.
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.
LP Information, Inc. (LPI) ' newest research report, the “Ultrasonic Metal Welding Machine Industry Forecast” looks at past sales and reviews total world Ultrasonic Metal Welding Machine sales in 2025, providing a comprehensive analysis by region and market sector of projected Ultrasonic Metal Welding Machine sales for 2026 through 2032. With Ultrasonic Metal Welding Machine sales broken down by region, market sector and sub-sector, this report provides a detailed analysis in US$ millions of the world Ultrasonic Metal Welding Machine industry.
This Insight Report provides a comprehensive analysis of the global Ultrasonic Metal Welding Machine landscape and highlights key trends related to product segmentation, company formation, revenue, and market share, latest development, and M&A activity. This report also analyzes the strategies of leading global companies with a focus on Ultrasonic Metal Welding Machine portfolios and capabilities, market entry strategies, market positions, and geographic footprints, to better understand these firms’ unique position in an accelerating global Ultrasonic Metal Welding Machine market.
This Insight Report evaluates the key market trends, drivers, and affecting factors shaping the global outlook for Ultrasonic Metal Welding Machine and breaks down the forecast by Type, by Application, geography, and market size to highlight emerging pockets of opportunity. With a transparent methodology based on hundreds of bottom-up qualitative and quantitative market inputs, this study forecast offers a highly nuanced view of the current state and future trajectory in the global Ultrasonic Metal Welding Machine.
This report presents a comprehensive overview, market shares, and growth opportunities of Ultrasonic Metal Welding Machine market by product type, application, key manufacturers and key regions and countries.
Segmentation by Type:
Spot Ultrasonic Metal Welder
Wire Splicing Ultrasonic Metal Welder
Seam Ultrasonic Metal Welder
Tube Sealer Ultrasonic Metal Welder
Others
Segmentation by Form:
Portable Type
Desktop Type
Segmentation by Frequency:
20 kHz
30 kHz
40 kHz
Segmentation by Application:
Power Batteries
Automotive Wiring Harnesses
Power Semiconductors IGBT
Others
This report also splits the market by region:
Americas
United States
Canada
Mexico
Brazil
APAC
China
Japan
Korea
Southeast Asia
India
Australia
Europe
Germany
France
UK
Italy
Russia
Middle East & Africa
Egypt
South Africa
Israel
Turkey
GCC Countries
The below companies that are profiled have been selected based on inputs gathered from primary experts and analysing the company's coverage, product portfolio, its market penetration.
Emerson (Branson)
Sonics & Materials
Schunk
Telsonic
SBT Ultrasonic Technology
TECH-SONIC
Kormax System
Chuxin M&E
JD Sonic-Tech
Wuxi Hengshengte
HYUSONIC
Key Questions Addressed in this Report
What is the 10-year outlook for the global Ultrasonic Metal Welding Machine market?
What factors are driving Ultrasonic Metal Welding Machine market growth, globally and by region?
Which technologies are poised for the fastest growth by market and region?
How do Ultrasonic Metal Welding Machine market opportunities vary by end market size?
How does Ultrasonic Metal Welding Machine break out by Type, by Application?
Please note: The report will take approximately 2 business days to prepare and deliver.
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.
LP Information, Inc. (LPI) ' newest research report, the “Ultrasonic Metal Welding Machine Industry Forecast” looks at past sales and reviews total world Ultrasonic Metal Welding Machine sales in 2025, providing a comprehensive analysis by region and market sector of projected Ultrasonic Metal Welding Machine sales for 2026 through 2032. With Ultrasonic Metal Welding Machine sales broken down by region, market sector and sub-sector, this report provides a detailed analysis in US$ millions of the world Ultrasonic Metal Welding Machine industry.
This Insight Report provides a comprehensive analysis of the global Ultrasonic Metal Welding Machine landscape and highlights key trends related to product segmentation, company formation, revenue, and market share, latest development, and M&A activity. This report also analyzes the strategies of leading global companies with a focus on Ultrasonic Metal Welding Machine portfolios and capabilities, market entry strategies, market positions, and geographic footprints, to better understand these firms’ unique position in an accelerating global Ultrasonic Metal Welding Machine market.
This Insight Report evaluates the key market trends, drivers, and affecting factors shaping the global outlook for Ultrasonic Metal Welding Machine and breaks down the forecast by Type, by Application, geography, and market size to highlight emerging pockets of opportunity. With a transparent methodology based on hundreds of bottom-up qualitative and quantitative market inputs, this study forecast offers a highly nuanced view of the current state and future trajectory in the global Ultrasonic Metal Welding Machine.
This report presents a comprehensive overview, market shares, and growth opportunities of Ultrasonic Metal Welding Machine market by product type, application, key manufacturers and key regions and countries.
Segmentation by Type:
Spot Ultrasonic Metal Welder
Wire Splicing Ultrasonic Metal Welder
Seam Ultrasonic Metal Welder
Tube Sealer Ultrasonic Metal Welder
Others
Segmentation by Form:
Portable Type
Desktop Type
Segmentation by Frequency:
20 kHz
30 kHz
40 kHz
Segmentation by Application:
Power Batteries
Automotive Wiring Harnesses
Power Semiconductors IGBT
Others
This report also splits the market by region:
Americas
United States
Canada
Mexico
Brazil
APAC
China
Japan
Korea
Southeast Asia
India
Australia
Europe
Germany
France
UK
Italy
Russia
Middle East & Africa
Egypt
South Africa
Israel
Turkey
GCC Countries
The below companies that are profiled have been selected based on inputs gathered from primary experts and analysing the company's coverage, product portfolio, its market penetration.
Emerson (Branson)
Sonics & Materials
Schunk
Telsonic
SBT Ultrasonic Technology
TECH-SONIC
Kormax System
Chuxin M&E
JD Sonic-Tech
Wuxi Hengshengte
HYUSONIC
Key Questions Addressed in this Report
What is the 10-year outlook for the global Ultrasonic Metal Welding Machine market?
What factors are driving Ultrasonic Metal Welding Machine market growth, globally and by region?
Which technologies are poised for the fastest growth by market and region?
How do Ultrasonic Metal Welding Machine market opportunities vary by end market size?
How does Ultrasonic Metal Welding Machine break out by Type, by Application?
Please note: The report will take approximately 2 business days to prepare and deliver.
Table of Contents
108 Pages
- *This is a tentative TOC and the final deliverable is subject to change.*
- 1 Scope of the Report
- 2 Executive Summary
- 3 Global by Company
- 4 World Historic Review for Ultrasonic Metal Welding Machine by Geographic Region
- 5 Americas
- 6 APAC
- 7 Europe
- 8 Middle East & Africa
- 9 Market Drivers, Challenges and Trends
- 10 Manufacturing Cost Structure Analysis
- 11 Marketing, Distributors and Customer
- 12 World Forecast Review for Ultrasonic Metal Welding Machine by Geographic Region
- 13 Key Players Analysis
- 14 Research Findings and Conclusion
Pricing
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