Ultrasonic Splicing Technology VS Soldering, Resistance Welding

To most wire and cable companies, resistance welding and soldering have been the conventional techniques for connecting and splicing wires for years. As seen, these time-tested and frequently used procedures have shown to be dependable solutions for a wide range of jobs. In certain situations, involving stainless steel, nickel and slighter wire bundling; resistance welding holds the spot as the ‘go-to’ method.

Consequences of conventional techniques

Though very commonly practiced, joining two or more wires in this process will risk causing excessive electrode wear. In addition, negative influence on the structural characteristics of the material being connected can be seen. As a consequence of this, the demand of constant supervision from welder/splicer(s) is necessary. Moreover, although soldering is an excellent option for many applications, it does have its certain disadvantages. For instance, one of the challenges is the supervision of the application process within the manufacturing setting. Too, another challenge is the high temperature of facilities where these cables are assembled, where quality of soldering is jeopardize. 

Solution alternatives to conventional techniques through ultrasonic splicing

Due to the automotive industry’s constant demand of dependable wire connectors, Z-Tronix has brought a solution to the problem by supplying custom harnesses, wires connected through ultrasonic splicing. So, why does the automotive industry look for this type of innovation you may ask? Easy, because of copper’s nature, excellent shielding against corrosion, lower cost benefits and  electrical resistance. Some common ways companies in the industry of wire use it are by splicing smaller strands of copper into:

  • premanufactured wire
  • manufacturing of wire harnesses 
  • compaction of the wires themselves

Next, it’s important to know what type of application it will be for. The answer to that, the Ultrasonic Splicing Technology machine is more than capable of bonding solutions that are integrated by copper and aluminum.

Common Uses  Specs and Benefits 
Single splices and splice sequences  Cross sections from 0.26mm² to 40 mm² 
High-voltage multi-conductor cables  Large cross-sectional range with the same machine 
Twisted data cables  Easy to operate and maintain 
Inline and end splices  Production server for distributing orders between Telso®Splice systems 
Center-strip splice  Quality check with Telsonic Quality Control Center TQCC 
Wire compaction   
Copper and aluminum wires   


What can we do for you?

Z-Tronix, being a problem-solving company, began to acquire Telsonic Ultrasonic products over five years ago, as the electrical automotive industry grew.  The standards and demanding regulations in the automotive industry have challenged and motivated Z-Tronix to become equipped and produce custom cable assemblies and wire harnesses to be only of the highest quality and grade. Consequently this has narrowed and filtered the companies who can fulfill these solutions, leaving Z-Tronix as an assembling company that is capable of manufacturing custom wire harnesses with ultrasonic splicing technology for all industries who are in seek of quality, durability and dependable wire harnesses. Regardless of industry, ultrasonic splicing is a great technology to request at Z-Tronix for longer-lasting product bonding and conductivity. If you agree, call us now, and speak with our representatives to learn about this technology and whether it’s the best option for your application.