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The Science

Ultrasonic metal welding uses high-frequency vibrations to make metal surfaces rub against each other, breaking down the oxide layer on the metal's surface. The downforce applied by the UAM system collapses local asperities allowing the metal surfaces to be in intimate contact creating a true metallurgical bond. The process creates strong bonds between the metals, making it ideal for joining dissimilar materials and producing precise, high-quality welds.

The Printing

A single layer is made by welding a thin metal foil (0.005-0.010 inches) onto a metal substrate as the ultrasonic head moves over the surface. It welds adjacent areas in a raster pattern until the whole layer is welded, with each weld overlapping neighboring ones to ensure seamlessness. This process is repeated as more foils are stacked vertically (in the z direction), gradually forming a solid metal shape.

The Machining

With the unique hybrid additive/subtractive process, final shapes can be machined with high accuracy and excellent surface finish. At the same time, the CNC milling capability can be used for producing complex internal shapes and for embedding electronics and sensors (e.g., fiber optics and thermocouples). No additional post-processing is required after the part is built.

The Possibilities
Are Endless


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FAQs — Materials

Do you provide the feed material or can it be purchased from any raw metal provider? What are the requirements for it (geometrical form, dimensions and tolerances, weight, material)?

I have read that the machine usually operates with 1” wide metal tape. Can it feed on tapes with different width? On sheets? If so, what are the limitations?

What materials work in the UAM process?

What temperature does the metal reach during the ultrasonic welding process? We understand that it’s a cold process, but what is the maximum temperature we should expect?

How does the process affect embedded electronics? Are there limitations on sensitive equipment?

How does the welded material behave after the process? Can coating be applied to the manufactured parts same as to standard parts?

FAQs — Geometry

What is the surface finish? How close can you hold tolerances?

The machine lays tapes side by side with a small overlap, how sensitive the process to tolerances? How does the machine ensure it?

Are the layers waterproof? Gas proof?

What are the geometrical limitations of the process?

Have you tried support material?

What about overhung geometry?

How does the welded material behave after the process? Can coating be applied to the manufactured parts same as to standard parts?

FAQs — Process

How does an ultrasonic weld work? Is it a real weld?

What are the parameters which control the welding process?

What is the build rate?

How do you program the machine? Do I need a special file format?

What are the consumables for this machine?

Is the process of replacing milling tools an automated process or manual?

Are there any special safety instructions for the ultrasonic process that we should be aware of? Safety distance from working machine? Special safety equipment?

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