Ultrasonic welding systems for metal and plastic joints in automotive, battery and power electronics
STAPLA Ultraschall-Technik GmbH
Kelsterbach (DE)New on Amplifa
About STAPLA / Schunk Sonosystems
STAPLA Ultraschall-Technik GmbH was founded in 1982 and is today part of the Schunk Group under the Schunk Sonosystems brand world. The company develops and manufactures ultrasonic welding systems for metals and plastics. In ultrasonic metal welding, metallurgically pure, high-strength joints are produced without filler materials and without melting, for example for wire harnesses with cross-sections from 0.08 to 200 mm², for battery contacting from cell production through to battery contacting, for gas-tight sealing of filling valves in refrigeration technology, and for solder-free joints in power electronics (IGBT and IPM modules). With the integration of the MS Ultraschall Technologie Group (UTG), the portfolio was extended to include ultrasonic plastic welding, which is used among other things in medical technology, electronics and packaging. In addition to systems, the company offers consulting and trial welds (Proving Trials). The headquarters is located in Kelsterbach near Frankfurt am Main; historically there was a second site in Boston, Massachusetts.
- Site
- Kelsterbach
- Processes
- Ultrasonic metal welding, Ultrasonic plastic welding, Ultrasonic welding of wire harnesses (cross-sections 0.08 to 200 mm²), Ultrasonic welding for battery technology (cell production through to battery contacting), Ultrasonic welding for refrigeration technology (gas-tight sealing of filling valves), Ultrasonic welding for power electronics (IGBT/IPM modules, solder-free joining technology), Consulting (Consultancy), Trial / Proving Welding Trials
- Materials
- Ultrasonic Metal Welding, Ultrasonic Plastic Welding, L-Splice, BW20, MINIC-III, DS20-III (TF variant)
- Founded
- 1982
- Industries
- Automotive, Battery technology, Refrigeration technology, Power electronics, Electronics, Medical technology
- 01
Consulting and trial welds (Proving Trials)
- 02
System development and engineering
- 03
Manufacturing of the ultrasonic welding systems
- 04
Process monitoring and commissioning
- 05
Service and technical support
Processes and Systems
Ultrasonic Metal Welding
Produces metallurgically pure, high-strength joints without filler materials or melting, e.g. for cable splices and battery contacts.
Ultrasonic Plastic Welding
Chemical-free, precise joining process for plastics, particularly in medical technology, electronics and packaging.
L-Splice
Ultrasonic metal welding system for conductor cross-sections up to 200 mm² in the wire harness sector.
BW20
Modular ultrasonic welding system, used in battery technology from cell production through to battery contacting.
MINIC-III
Ultrasonic welding system for wire applications.
DS20-III (TF variant)
System for ultrasonic metal welding of wire to terminal in wire harness manufacturing.
Sites
Kelsterbach
DEHeadquarters with development, manufacturing and sales
- Materials
- Metals, plastics
- Ultrasonic metal welding system L-Splice
- Modular welding system BW20
- Welding system MINIC-III
- Welding system DS20-III (TF)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Ultrasonic metal weldingJoining | – | – | – | – | Metals |
| Ultrasonic plastic weldingPlastics | – | – | – | – | Plastics |
| Ultrasonic welding of wire harnesses (cross-sections 0.08 to 200 mm²)Joining | – | – | – | – | Metals (cables/wires) |
| Ultrasonic welding for battery technology (cell production through to battery contacting)Joining | – | – | – | – | Lithium-ion battery components |
| Ultrasonic welding for refrigeration technology (gas-tight sealing of filling valves)Joining | – | – | – | – | Metals |
| Ultrasonic welding for power electronics (IGBT/IPM modules, solder-free joining technology)Joining | – | – | – | – | Metals |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Ultrasonic metal welding system | Schunk Sonosystems / STAPLA L-Splice | – | Cross-sections up to 200 mm² | – | – |
| Ultrasonic metal welding system (modular system) | Schunk Sonosystems BW20 | – | – | – | – |
| Ultrasonic welding system for wire applications | Schunk Sonosystems MINIC-III | – | – | – | – |
| Ultrasonic metal welding system (wire-to-terminal, TF variant) | Schunk Sonosystems DS20-III | – | – | – | – |
Additional services
History
- 1982
Foundation of Stapla Ultraschall-Technik GmbH; later international orientation with headquarters in Frankfurt/Kelsterbach and a site in Boston, Massachusetts.
- 1998
Dr. Harald Frank became Managing Director (CEO/CFO) of the STAPLA companies in Frankfurt and Boston.
- 2005
Consolidation of the German ultrasonic metal welding activities within the Schunk Group.
Integration of the MS Ultraschall Technologie Group (UTG) into Schunk Sonosystems; expansion to include ultrasonic plastic welding.