ABOUT US
Agile Ultrasonics designs and builds ultrasonic end effectors that enable continuous joining and shaping of thermoplastic composites. Our technology includes adaptable, system agnostic end effectors that can be easily integrated into robotic, CNC, ATL or dedicated work cell environments.​ Options include continuous ultrasonic welding without energy directors or film inserts
IN PRACTICE, WE DELIVER PRECISE AMOUNTS OF ENERGY INTO A COMPOSITE MATERIAL TO CAUSE A HEAT EVENT. WHAT YOU DO WITH THAT ENERGY CAN VARY WIDELY.
The problem
Agile is developing systems and solutions for welding thermoplastic composites (TPC) in response to evolving market demands.
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Many of our customers are actively engaged in R&D efforts to integrate welding processes into their manufacturing. If TPCs are going to scale in use, high-rate, low power technologies need to be developed for joining and welding. Currently available options include:​
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Adhesives and fasteners
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Resistance welding
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Induction welding
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Laserwelding
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Traditional ultrasonic welding and tacking
However, there is no single approach that has been shown to be consistently and repeatably scalable. No ONE technology will do it all, yet each has value. Often, the solution is a hybrid, combining multiple technologies, each contributing what they do best.​
Capabilities
Agile Ultrasonics
Laser
Induction
Heat at point of contact only
Yes
Narrow area
Medium area
Precise heat control
Yes
Yes
Medium
Compaction roller required
No
Yes
Yes
Preform tack and place
Yes
Yes
No
Multiple ply lay-down
Yes
One ply at a time
One ply at a time
Full-width multi-ply compaction/debulking
Yes
1⁄8" to 12"+
No
limited to standard tape widths
No
limited to standard tape widths
Weld laminates
Yes
No
Yes
Continuous run scan weld
Yes
No
Yes
EH&S requirements
Minimal
No entry while in operation
Voltage and EMF
End effector size
Compact
Medium
Large
Efficient power consumption
Yes
Yes
Medium
The solution
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At Agile, we're developing polymer composite joining systems that enable hybrid joining technologies. We're opening the door to greater versatility and collaborating wherever possible with supply chain partners to develop broader thermoplastic composite joining capabilities.
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Continuing to refine our CUW process
Agile Ultrasonics' continuous ultrasonic welding (CUW )technology represents a major advancement opportunity in both space-based and terrestrial composite manufacturing. Unlike conventional ultrasonic welding systems, Agile has commercialized its technology as a modular, adaptable robot-agnostic end effector. This flexibility will be crucial for unlocking new opportunities for high-performance composites in aviation, urban air mobility, defense, automotive, consumer and industrial markets, as well as manufacturing in space. With continued collaboration and industry support, Agile is set to define the next era of structural materials joining.