Ultrasonic Compaction as a Process

Powerful and future-oriented

WUSTEC’s fully automated ultrasonic compression process eliminates the need for traditional crimping or pressing. Ultrasonic welding homogeneously welds the single strands to form a purely metallic unit.

In conventional wire processing, single strands are often fitted with ferrules. These are necessary as the fine copper wires of the strand could otherwise be damaged by the fastening screw during installation and therefore no longer guarantee a perfect electrical contact. Ultrasonic compaction eliminates the need for ferrules.

The advancing miniaturization in many sectors of industry and automotive manufacturing is also having an impact on wire ends. Due to the demand for ever smaller devices, ferrules often prove to be unsuitable due to the increased cable cross section. In this case, the ultrasonically compacted strands offer a significant advantage due to their up to 50% smaller cross section of the contact point.

WUSTEC has been a leader in the application and further development of ultrasonic compaction for over 15 years. With a deep understanding of the market requirements and technical challenges, WUSTEC has developed a fully automated solution that not only increases production efficiency, but also improves the quality of the final products. By investing in state-of-the-art technologies and continuous research and development, WUSTEC has perfected ultrasonic compaction and offers its customers tailored solutions.

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Advantages of Ultrasonically Compacted Strands

Cost-effective and innovative

Thanks to our fully automated process, the strands can be ultrasonically compacted to the desired length and size and processed individually for your specific application.

Highest precision with the lowest possible transition resistance

Ultrasonic welding eliminates the need to melt the strands. The homogeneous connection is highly resistant to corrosion and conducts particularly well. The process has a positive effect on heat development and increases the reliability of the products.

Ability to connect multiple strands

The ultrasonic welding process also makes it possible to connect several cores. The resulting node is extremely compact and stands out for its high mechanical strength.

Areas of Application

Advanced and universally suitable

Ultrasonically compacted strands can be manufactured for cross sections from 0.5 to 35 mm². This makes the technology versatile for meter strands and wiring bridges in the area of switch cabinet construction as well as in the lighting and automotive industry.

Perfect for miniaturization in cable assembly

Ultrasonic compaction makes smaller wire end cross sections possible. The contact point is compressed to the smallest possible size by the mechanical process. This means that these cables offer space savings of up to 50% at the contact point compared to conventional cable ends with ferrules, for example.

Cost savings and efficiency

Ultrasonic compaction is a fast and efficient process step in automated wire processing. In addition, no ferrules, crimp contacts, or tinning is required. This not only saves material, but also delivers precise results with high reproducibility.

Cutting-edge technology

Ultrasonic compaction technology, led by WUSTEC, is a prime example of the future of switch cabinet construction. With a focus on efficiency, quality, and miniaturization, ultrasonic compaction opens up new opportunities for industry to meet the growing demands of modern electrical systems.


Have any questions?

Have we sparked your interest or do you have any questions about ultrasonically compacted strands? At WUSTEC, we offer our customers worldwide high-quality, efficient, and future-proof solutions. Contact us now for a no-obligation consultation.

Ronny Kaltschmid

Head of Sales and Marketing - Product Manager Manufacturing Platform