Ultrasonic Welding

Stylized black and white wire harness graphic showcasing Kato Cable’s advanced cable design

Ultrasonic Welding Solutions

Ultrasonic welding creates strong, low-resistance wire connections without solder, terminals, or added filler materials. Kato Cable provides wire-to-wire ultrasonic welding for custom harnesses and cable assemblies where electrical performance, compact design, and repeatable quality are critical.


Our team evaluates conductor size, splice configuration, application demands, and production requirements to develop a controlled welding process that supports reliable performance from prototype through full production.

Precision welding or soldering icon

Wire-to-Wire Ultrasonic Welding

Ultrasonic welding is a technique used to join two wires using high-frequency ultrasonic vibrations.


These vibrations generate localized frictional heat at the joint interface. The material melts slightly at the contact point. Pressure is applied, and the materials fuse together as they cool and solidify.


This is commonly used in automotive electronics and high-performance applications.

Black and white wire harness design element representing Kato Cable’s precision connectivity
Two female Kato Cable technicians inspecting a wiring board.

Process Control & Engineering Control Services

Process Control

Precision and consistency are at the heart of every custom cable solution. Our Process Control strategies ensure each assembly meets exact specifications, from initial concept to final production. Through rigorous quality checks, standardized procedures, and real-time monitoring, we optimize efficiency while maintaining the highest level of reliability.

Engineering Control

From concept to completion, Engineering Control ensures every design is optimized for functionality, manufacturability, and long-term performance.  Our expert team evaluates form, fit, and function, applies industry best practices and testing protocols, and leverages innovative solutions to deliver high-quality and cost-effective cable and harness assemblies.

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Our Products are Proudly Made in the USA

The Kato Cable Advantage

The Kato Cable Advantage is a holistic approach to looking at the value that you bring to your customers, employees and community. Our customers relate directly to our responsiveness and engineering value, to the investments that we have made into efficiencies and automation, and to the key metrics of industry leading Quality and On Time Delivery. Our employees relate to a sense of inclusion, an appreciation and value to feedback, and the philosophy of making improvements every day. Our community relates to our growth and volunteerism and leadership that we strive for in our region. Together these attributes and values truly deliver the Kato Cable Advantage!

Quality & Reliability

Delivering precision-engineered wire harnesses, cable assemblies, and electro-mechanical assemblies that meet the highest industry standards.

Innovation

Continuously improving processes and technologies to provide cutting-edge solutions for diverse industries.

Customer Commitment

Building strong partnerships through collaboration, responsiveness, and tailored solutions.

Our Certifications

DQS quality management logo.
WHMA-A-620 logo.
cURus UL-Approved logo

Ultrasonic Welding FAQs

  • How does ultrasonic welding improve electrical conductivity and joint reliability?

    Ultrasonic welding creates a strong, low-resistance bond without solder or added filler materials. The result is a compact, repeatable connection designed for reliable electrical and mechanical performance.

  • What wire materials, gauges, and splice configurations are compatible with ultrasonic welding?

    Compatibility depends on conductor material, wire gauge, strand construction, and splice size. Kato Cable evaluates each application to determine the right tooling, weld parameters, and process controls.

  • How does Kato Cable monitor and validate ultrasonic weld quality?

    Kato Cable uses controlled weld parameters, documented work instructions, and production testing to support consistent quality. Validation may include visual inspection, pull-force testing, dimensional checks, and electrical testing.

  • When should an OEM choose ultrasonic welding instead of crimping or soldering?

    Ultrasonic welding is often a strong choice when an application requires a compact, low-resistance connection without terminals or solder. Kato Cable helps customers determine whether it is the best fit based on performance, design, and production requirements.

  • Can Kato Cable scale an ultrasonic welding process from prototype to production?

    Yes. Kato Cable can support projects from early design and prototyping through production launch and ongoing manufacturing. Our team works with customers to improve manufacturability, establish process controls, and support long-term production needs.

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Ultrasonic Welding Contact Us

Looking for Support?

Our team is here to help. Whether you’re looking for a custom solution or need support with an existing project, we’re just a message away. Reach out today, and let’s find the right solution for you.