EWI Logo on Product Example

Ultrasonic Processes


Ultrasonic technology offers a high-power tool for abroad range of manufacturing applications.

At EWI, we apply our expertise in ultrasonic technology to applications beyond ultrasonic welding and nondestructive evaluation (NDE), including cutting, machining, package sealing, additive manufacturing, powder compaction, and wire drawing. We enable manufacturers to use ultrasonic-based processes to help them:

  • Optimize ultrasonic weld joint design
  • Test and evaluate processes and technologies
  • Design and fabricate high-powered ultrasound (HPU) systems – e.g., sonotrodes customized for a specific application

EWI’s ultrasonics team has led the industry in ultrasonic research and published foundational works in the field. With our deep understanding of ultrasonic technology and our cross-departmental strengths, we achieve our clients’ production or design goals in innovative and unexpected ways.



That’s how we surmount unique challenges with customized ultrasonic solutions to further the success of our partners. Our ultrasonics team is ready to help your organization.

Spotlight on Ultrasonic Package Sealing

UltraThinSeal Logo

EWI UltraThinSeal, an affiliate of EWI, is a pioneer of ultrasonic packaging technology. The company spun out of EWI to bring its unique technology to packaging-industry players worldwide.

The EWI UltraThinSeal system utilizes the basic mechanics of ultrasonic welding in patented ultrasonic technology that joins extremely delicate materials – snack package films – to create strong seals as small as 1mm. Compared to traditional thermal sealing, this system produces better seal quality and far less waste, and it’s viable for biodegradable materials and PLA. 

Our Core Ultrasonic Processes

EWI’s range of ultrasonic welding and process expertise includes the following. 

  • High-powered ultrasound (HPU) system design
  • Plastics joining
  • Microjoining
  • Ultrasonic metal welding
  • Additive manufacturing
  • Ultrasonically assisted forming, wire drawing, soldering, and brazing
  • Friction reduction
  • Cleaning and defoaming
  • Food processing and package sealing (see below)
  • Ultrasonic machining

Ultrasonic Equipment & Lab Resources

Our experts are well-equipped with the resources they need to think big with ultrasonics.


Ultrasonic metal welding systems (lateral drive,wedge-reed, torsion, seam)

  • Frequencies from 15 to 60 kHz
  • Power from 500 to 10,000 W


Ultrasonic plastic welding systems

  • Frequencies from 15 to 60 kHz
  • Power from 500 to 4.5 kW


Ultrasonic package sealing equipment

  • Vertical Form Fill Seal (VFFS) demonstration unit
  • Benchtop sealing equipment for feasibility
  • Dual-face rotary package welding system


Lead-free ultrasonic soldering and brazing equipment


Per-unit (PU) system testing and evaluation equipment

  • 1D and 2D laser virometer
  • Impedance analyzer
  • Spectrum analyzer
  • High-power motor-generator transducer test bench
  • Infrared thermography for thermal profiling


High-powered ultrasound (HPU) design, modeling and testing equipment

  • Creo Parametric
  • SolidWorks
  • Abaqus
  • Ansys
  • Piezotran

Ultrasonic Welding & Process Development

Developing new technologies or modifying existing equipment starts with careful process development. The EWI ultrasonics team approaches our work scientifically to achieve results. These services support that approach:

  • Process development
  • Design of experiments (DOE)
  • Testing and evaluation of high-powered ultrasound (HPU) systems
  • Ultrasonic weld testing (e.g., post-weld joint integrity)
  • Ultrasonic tool design 

View Ultrasonic Processes Resources

Ultrasonic Thin Film Package Sealing - EWI UltraThinSeal


Hybrid Ultrasonic Spot Welding of High Strength Materials

Aluminum and steel are primary materials used throughout automotive and aerospace structures.

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Ultrasonic Metal Welding


Ultrasonic Plastic Welding


An Approach to Determine Minimum Amplitude Required for Ultrasonic Welding

Ultrasonic welding is one of the most common plastic welding processes used in industry.

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Ultrasonic Soldering


Learn more about our ultrasonic capabilities

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