Ultrasonic Welding for EV Wire Harnesses – High Strength & Conductivity

For new energy vehicle (EV) wire harness assembly, ultrasonic welding has become the preferred technology – and for good reason. It delivers higher tensile strength and better electrical conductivity than crimping or soldering.

Why ultrasonic welding outperforms traditional methods:

✅ Higher tensile strength
Ultrasonic solid-state bonding creates a true metallurgical joint without melting. Typical pull strength reaches 90–95% of the wire's original strength, exceeding crimping (typically 70–80%) by 20–30%. This ensures reliable performance under vibration and thermal cycling.

✅ Excellent conductivity
No filler materials, no oxidation. Contact resistance is low and stable, while crimped connections often show higher initial resistance and gradual drift over time.

✅ No heat damage
Soldering and resistance welding damage wire insulation. Ultrasonic welding keeps the process well below 150°C, protecting thin-walled EV wire jackets.

✅ Consistent & repeatable
Automated process control with closed-loop monitoring eliminates operator variables. Every weld meets the same quality standard – crimping is more sensitive to tool wear.

✅ Dissimilar metals ready
Aluminum wire to copper terminal? No problem. Ultrasonic welding avoids brittle intermetallic compounds.

Typical applications:

HV cable to terminal (25mm², 35mm², 50mm², 70mm²)

Wire harness bundling

Battery pack internal connections

Charging inlet cables

Switch to ultrasonic – get stronger, more conductive, and more reliable EV wire harness connections.

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