Application Engineering

At Sonitek, we bring over 30 years of experience working with more than 3,500 manufacturers worldwide. Our team of engineering experts specializes in Ultrasonic Tooling, Thermal Heat Staking Tooling, and Air Press Tooling, providing you with unparalleled guidance on tooling design, optimization, and application-specific recommendations.

We specialize in optimizing tooling processes, ensuring proper tool performance, and providing design guidelines for ultrasonic welding, thermal heat staking, and air press applications. While we don't design your entire product, we offer crucial insights to help you optimize your parts for these joining technologies.

Our Commitment to Tooling Excellence

Our commitment to excellence is evident in our approach to tooling and application guidance:

• We maintain a fully equipped lab for testing customer applications and optimizing tooling performance across all our technologies.
• We employ advanced computer modeling with 3D finite element analysis (FEA) to simulate real-world conditions for our tooling, identifying potential issues before they occur in the field.
• Our comprehensive engineering expertise allows us to:
• Design tooling to optimal specifications for ultrasonic, thermal heat staking, and air press applications
• Assess vibration frequency, amplitude, and stress for ultrasonic horns and tooling
• Evaluate heat distribution in thermal heat staking tools
• Analyze pressure requirements and force distribution for air press tooling
• Identify stresses, predict performance, and analyze tooling failures
• Provide design guidelines for energy directors in ultrasonic welding and best practices for heat staking to ensure proper joining
• Troubleshoot and diagnose malfunctioning or underperforming tooling in any of our specialties

Our diverse team of engineers, including manufacturing, design application, and sales specialists, meticulously evaluates all options to deliver the most productive, cost-effective, and ergonomic tooling solutions for your specific needs in ultrasonic welding, thermal heat staking, or air press applications. While we don't design your entire product, we provide crucial guidance to ensure your parts are optimized for these joining technologies.

At Sonitek, we focus on ensuring reliable and repeatable tooling performance for your assembly process. Our fast and accurate methods for tooling design and optimization are the answer to your assembly challenges, regardless of the joining technology required.