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Continuous Ultrasonic Welding Without Energy Directors, Film Resin Layers or Other Types of Inserts 

‚ÄčAgile Ultrasonics designs and manufactures ultrasonic welding solutions optimized for thermoplastic composite welding applications.  The company's technology supports continuous welding of thermoplastics without the need for energy directors, film layers or inserts. 

Our approach is both disruptive and breakthrough in the ultrasonics industry.  Without the need for energy directors applications can be developed using native format materials such as carbon fiber reinforced unidirectional tape, braid and preformed multi-ply components of varying width, length and thickness.  The result is creative freedom of design leading to lower overall cost of production through reduced tooling, labor and energy consumption. 

Agile technology supports continuous tack in place for ATL applications such as stamp forming, welding preformed components rather than using adhesives and fasteners, in-situ debulking, pre-consolidation and multi-ply consolidation on the fly. 

Ultrasonic Scan Welding of Continuous Fiber Thermoplastic tape to 3D Printed Structures represents an entirely new field of use where we've shown that we can double the strength of 3D printed components through continuous ultrasonic additive welding.  Contact us for a paper on this approach. 

Agile is engaged in a multitude of system design projects with industry leading component makers in aerospace, automotive and consumer sporting goods.  We collaborate with customers to optimize ultrasonic features for specific materials and outcomes. 

Founded on patented technology Agile's approach to ultrasonic welding enables precisely controlled through thickness heating that delivers desired consolidation effects in an ambient open-air environments.  Heat is generated only at the point of consolidation, fast weld times are measured in milliseconds and weld area is scalable to width, length and thickness.

Our approach opens the door to lighter, thinner less expensive components, less tooling with greater prototyping and iteration potential permitting engineers to rethink component design material options.