Abstract: An ultrasonic welding system, comprising at least one sonotrode configured to ultrasonically weld a part or component having a complex geometry, wherein, the at least one sonotrode has a shape generally corresponding to the shape of the part or component to be welded, and wherein the sonotrode includes an input face; an energy input located on the input face; an output face positioned opposite the input face; and a body positioned between the input face and the output face; and wherein the at least one sonotrode has a non-uniform distribution of mass.

Abstract: A system for consolidating materials, comprising a sonotrode configured to direct ultrasonic energy into materials to be consolidated, wherein the materials to be consolidated have both a glass transition temperature and a melting temperature; a non-rigid consolidating material in proximity to the sonotrode, wherein the non-rigid consolidating material and sonotrode define a region therebetween for receiving the materials to be consolidated, and wherein the non-rigid consolidating material has a glass transition temperature that is higher than the glass transition temperature of the materials to be consolidated and a melting temperature that is higher than the melting temperature of the materials to be consolidated.

Abstract: A system for ultrasonic consolidation of fiber reinforced thermoplastics, comprising a first component that is either an inner non-resonant mandrel or an inner sonotrode; a second component that is either an outer non-resonant mandrel or an outer sonotrode, wherein the first and second components are configured to receive fiber reinforced thermoplastic materials therebetween, wherein the inner sonotrode and the outer sonotrode are both configured to direct ultrasonic energy into the fiber reinforced thermoplastic materials, wherein the outer sonotrode produces radial displacement against the inner non-resonant mandrel, or wherein the inner sonotrode produces radial displacement against the outer non-resonant mandrel, or wherein the inner sonotrode produces radial displacement against the outer sonotrode, or wherein the outer sonotrode produces radial displacement against the inner sonotrode, and wherein the radial displacement generates compressive stress within the fiber reinforced thermoplastic materials th

Abstract: An ultrasonic welding system, comprising at least one sonotrode configured to ultrasonically weld a part or component having a complex geometry, wherein, the at least one sonotrode has a shape generally corresponding to the shape of the part or component to be welded, and wherein the sonotrode includes an input face; an energy input located on the input face; an output face positioned opposite the input face; and a body positioned between the input face and the output face; and wherein the at least one sonotrode has a non-uniform distribution of mass.

Abstract: A system for consolidating materials, comprising a sonotrode configured to direct ultrasonic energy into materials to be consolidated, wherein the materials to be consolidated have both a glass transition temperature and a melting temperature; a non-rigid consolidating material in proximity to the sonotrode, wherein the non-rigid consolidating material and sonotrode define a region therebetween for receiving the materials to be consolidated, and wherein the non-rigid consolidating material has a glass transition temperature that is higher than the glass transition temperature of the materials to be consolidated and a melting temperature that is higher than the melting temperature of the materials to be consolidated.