Custom Ultrasonic Horns & Sonotrodes
Custom ultrasonic horns and sonotrodes machined and tuned to your part — titanium, aluminium or tool steel, 15–40 kHz, from standard round horns to complex sonotrodes, blades and engraved anvils.
The wear part that is never standard
The horn is the only part of the stack that touches your product, so its geometry sets the joint and its tuning sets the process. A horn that is merely the right size is not enough: each one is designed for its frequency, machined to the drawing and then measured on the tuning bench until it resonates where it should.
Inputs are simple - a 3D file, a drawing or a sample part. Material is chosen for the job: titanium for long life and low loss, aluminium for soft plastics and speed, tool steel where abrasion or a cutting edge demands it.
How a horn is made
The geometry is designed and frequency-simulated before a chip is cut, then machined and finally measured on the tuning bench - so you know the horn is on frequency before it reaches your press.
Design & simulation
Horn geometry is modelled and frequency-simulated for your part and your generator.
CNC machining
Complex contours are cut and finished on our own machining centres.
Tuning
Each horn is measured and adjusted on the tuning bench until it resonates correctly.
Record & dispatch
A measured resonance record travels with every horn, so there is no guessing on delivery.
Pick the profile that matches the joint
Ordering specification
| Item | Options |
|---|---|
| Materials | Titanium alloy / aluminium / tool steel |
| Frequencies | 15 / 20 / 28 / 30 / 35 / 40 kHz |
| Types | Round, stepped, slotted, complex, blades, anvils |
| Design input | 3D file, drawing or sample part |
| Tuning | Measured and tuned per horn |
| Re-facing | Worn horns re-faced and re-tuned |
| Lead time | Standard profiles from days to weeks |
| Note | Urgent replacement - common sizes are often in stock |
One workshop machines the full range
Welding horns for press and automation welding from 15 to 40 kHz, cutting blades for food, fabric and rubber, engraved anvils that carry textile patterns and lace motifs, and special profiles cut to drawing.
Whatever the joint, the horn is cut for the generator it will run with, so amplitude at the weld stays consistent across the whole plant.
The four jobs a horn does
Welding horns
Press and automation welding from 15 to 40 kHz.
See plastic processing →
Cutting blades
Food, fabric and rubber blades tuned as cutting tools.
See food cutting →
Engraved anvils & special profiles
Textile patterns and lace motifs engraved in steel, plus stepped and special designs.
See non-woven & textile →Complete the stack
Send the 3D file for a horn quote
Design, simulation and a tuned, tested tool - all from one workshop. Send a 3D file, a drawing or a worn horn and we will measure, re-tune or make new.
Request a Quotation