Our Partners
Ultrasonic Welded Wire Harnesses
High-Performance, Low-Resistance Connections for Demanding Applications
At Celestix Industries India Pvt Ltd, we deploy ultrasonic welding as a foundational process in our advanced manufacturing ecosystem, particularly for custom wire harnesses where mechanical durability, electrical continuity, and dimensional accuracy are critical. This solid-state joining technology allows us to produce clean, high-performance welds without introducing additional materials, making it ideal for applications that demand zero-compromise reliability and long-term stability. From high-current EV battery interfaces to aerospace avionics wiring and high-speed industrial sensor networks, ultrasonic welding enhances both electrical and mechanical functionality. It enables us to meet the complex technical demands of industries including automotive, EV mobility, aerospace, defense, telecom, medical devices, industrial automation, and alternative energy systems—each with its own unique compliance, ruggedization, and performance standards.
Whether you're sourcing a durable ultrasonic harness for high-vibration environments, a smart ultrasonic wiring system for sensor arrays, or a compact ultrasonic harness optimized for space-sensitive systems, Celestix delivers. We're not just a trusted ultrasonic harness supplier—we're a responsive, collaborative partner who gets it right the first time. With in-house sonic welding harness capabilities and a deep bench of technical talent, we don’t just meet specs—we engineer confidence.
When long-term reliability, compactness, and signal integrity are non-negotiable, ultrasonic welding delivers critical performance advantages:
High-integrity joints without introducing new materials (no solder or flux)
Low contact resistance ensures clean, consistent current flow
Exceptional vibration resistance for dynamic, mobile, or high-shock environments
Seamless integration into DFM/DFA workflows and digital twin simulations
Fully compliant with IPC/WHMA-A-620, IATF 16949, and UL standards
Ultrasonic welding eliminates typical failure risks such as connector oxidation, thermal cycling degradation, and mechanical fatigue. The robust metal-to-metal bond structure provides enduring strength without excess bulk or assembly complexity—ideal for rugged welded harness assemblies in OEM sonic harness platforms.
Precision and performance aren't the only decision drivers. Ultrafast production, scalable reliability, and risk mitigation strategies are just as essential:
Minimized Defect Potential: Clean, secure welds reduce the risk of downtime, returns, and rework
Production Continuity: Built-in redundancies, lean execution, and flexible scheduling protect project timelines
Verified Quality: Every unit meets traceable, validated test protocols for full compliance
Project Versatility: Complex configurations and regulatory-intensive projects benefit from integrated engineering and QC frameworks
Trust in Every Detail: Proven delivery performance, transparent documentation, and advanced risk controls reflect operational excellence
No Solder, No Flux, No Contamination
Bonds are formed through high-frequency vibrations and pressure, eliminating the need for external heat or adhesives.
Low-Resistance Electrical Pathways
Ensures consistent power delivery and signal integrity, especially vital in high-current or high-frequency applications.
Solid-State Metal Fusion
Welds copper-to-copper or aluminum-to-copper with molecular-level bonding, producing durable and oxidation-resistant joints.
High-Speed, Repeatable Process
Reduces cycle times, minimizes labor dependency, and guarantees consistent quality across large production volumes.
Compact, Lightweight Joints
Ideal for space-constrained environments like EV battery packs and aerospace systems.
Ultrasonic welded wire harnesses serve a broad range of industries and functional requirements, offering exceptional mechanical strength and electrical reliability in applications where conventional crimps or soldering may fail. Celestix delivers reliable, UL-approved ultrasonic harness assemblies that support mission-critical systems.
EV Battery Harnesses & Busbars
High-current, high-voltage interconnections between battery modules, contactors, and power distribution units.
Powertrain and Engine Compartment Harnesses
Vibration-resistant, thermally stable terminations in internal combustion and electric vehicle platforms.
ADAS & Sensor Harnessing
Low-resistance, EMI-shielded signal pathways for radar, lidar, and ultrasonic sensors in automotive safety systems.
Multi-wire Splice Connections / Ultrasonic Spliced Harness
Reliable joins for wire groupings, reducing bulk and improving current distribution.
Aerospace Avionics and Communication Systems
High-density signal and power harnessing with fail-proof reliability in flight-critical environments.
Industrial Robotics and Automation
Dynamic-flex flexible sonic harness solutions for cable tracks, sensor arrays, and actuator clusters.
Over-Molded Terminal Assemblies
Sealed harness segments for medical devices, marine electronics, and rugged outdoor equipment.
High-Frequency Signal Lines / Sonic Control Wiring Harness
Welded splices and branches used in network infrastructure, telecom base stations, and RF systems.
Battery Management System (BMS) Interconnects
Precision-terminated sensing and control lines within lithium-ion battery packs.
Aerospace-Grade Connectors / Ultrasonic Terminal Harness
Welded leads pre-terminated to shielded or heat-resistant connectors in defense and aviation builds.
Medical Imaging and Diagnostic Devices
Harnesses for MRI, CT, and diagnostic systems where high-quality ultrasonic harness reliability and hygiene are critical.
Alternative Energy and Grid Systems
PV combiner boxes, inverter terminals, and energy storage systems demanding RoHS ultrasonic wiring and CE-certified ultrasonic harness standards.
Ultrasonic Sensor Harness & Ultrasonic Motor Harness
Reliable assemblies for sensing modules and motor applications in industrial, EV, and robotics settings.
Welded Connector Harness & Sonic Welded Power Cable
Strong joints for power and signal connectors that must endure vibration, temperature shifts, and long operating hours.
Prototype Ultrasonic Harness & Contract Welded Harness
Ideal for development cycles and scalable OEM manufacturing with full traceability.
Welding Frequency: 20–40 kHz
Weldable Materials: Copper, Tinned Copper, Aluminum
Wire Sizes Supported: 0.5 mm² to 50 mm² cross-section
Pull Strength: Exceeds 85% of parent material tensile strength
Testing & Validation:
Crimp Cross-Section Analysis
Pull-Force Testing
Continuity & High-Voltage Testing
Visual & Dimensional Inspection
Built to IPC/WHMA-A-620, IATF 16949, UL, and BIS standards
100% electrical testing and visual inspection
In-house lab for destructive/non-destructive testing
Certified Operators trained in ultrasonic welding protocols
Informed by detailed failure mode analysis, we mitigate root causes like inadequate strain relief, poor wire routing, and improper termination by design.
Celestix Ultrasonic Harness Expertise: Our team delivers unmatched insight in scalable ultrasonic wiring and smart ultrasonic wiring development.
Precision & Repeatability: Advanced ultrasonic welders and strict tool validation ensure uniform joint quality.
In-House Engineering Support: We assist in optimizing harness design for ultrasonic joining, aligned with best practices in DFM/DFA, CAD simulation, and rapid prototyping.
High Throughput Capacity: Scalable to meet both low-volume prototypes and large-volume production.
Failure Mitigation by Design: We incorporate design strategies that counter common failure modes like wire fatigue, short branches, thermal degradation, and connector oxidation.
Operational Trust: Proven reputation, reliable delivery, detailed documentation, and total cost control define our engagements.
DRIVE Culture: Dedication to Customers, Respect, Integrity, Value, and Excellence guides everything we do.