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Ultrasonic Tooling

Ultrasonic Horns made of different materials to provide the best solution for your welding application

Titanium is generally the preferred material for horns because it provides good fatigue strength, excellent acoustic properties and good surface hardness. Horns made by aluminum have excellent acoustic properties and are cost effective, mostly used for prototype horns or for horns requiring complex machining. Hardened steel horns are used for applications that cause severe wear and tear such as metal insertion, glass filled parts, and plunge cutting applications.

Various Plating to protect the horns

Chrome plating to seal aluminum horns to prevent oxidation, tungsten carbide coating for titanium horns to reduce wear & tear from glass reinforced material, TiN (Titanium Nitrate) used to coat food cutting horns to prevent wear and tear from abrasive material.

Slotted Horns to improve performance

Slots, in effect, break large horns into smaller, individual horns, to ensure uniform amplitude on the horn face and reduce internal stresses that may cause the horn to fail.

Best Service and Support

Experienced team of application and tooling engineers for rapid response. Captive world class machine centers to control quality and delivery. Latest in lab equipment for tooling inspection and testing. PDM system ensures repeat tooling is accurate and reduces delivery time.

Ultrasonic Tooling
Ultrasonic Tooling


Ultrasonic tooling (i.e., horns and fixtures) is a critical element in the plastics assembly process. Ultrasonic horns and fixtures must be designed to accommodate the requirements of a particular application. Applying the practices of a documented work process, Dukane’s highly skilled ultrasonic tooling engineers use the latest technology to design and manufacture durable, dependable horns and fixtures that can be used with Dukane plastics assembly equipment, as well as competitive equipment. Ultrasonic tooling engineers consider factors related to materials, engineering, and labor in the early design stage. Application specifics such as size, shape, material, function, etc., are all evaluated.

Key Features

  • Computer-aided design technology to design ultrasonic tooling
  • Design, manufacturing, and testing phases are meticulously documented
  • Structural and material data are stored for easy retrieval, review, and modification, if necessary
  • Finite Element Analysis lets an ultrasonic tooling engineer simulate a horn's performance before it is manufactured
  • Experience-enriched staff improves existing designs and investigates new ones via the latest technology tools and rigorous testing