Ultrasonic Welding Systems Market Size, Share, Growth, Forecast 2030

Ultrasonic Welding Systems Industry Prospective:

The global ultrasonic welding systems market size was worth around USD 560 million in 2022 and is predicted to grow to around USD 827 million by 2030 with a compound annual growth rate (CAGR) of roughly 5.0% between 2023 and 2030.       

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Ultrasonic Welding Systems Market: Overview

To form a solid-state weld between the components that are being held together under pressure, ultrasonic welding uses high-frequency ultrasonic acoustic vibrations that are locally applied. It is frequently used for connecting metals and polymers, particularly when the two materials are different. In ultrasonic welding, the materials are joined together without the need of connecting bolts, nails, solder, or adhesives. Because the temperature is kept much below the melting point of the metals being joined, any undesirable qualities that would result from the metal being exposed to high temperatures are avoided. The market growth of ultrasonic welding systems is being driven by the rising automotive industry, growing adoption in electronics, increasing medical device manufacturing, and advancements in the packaging industry.

Key Insights

• As per the analysis shared by our research analyst, the global Ultrasonic Welding Systems market is estimated to grow annually at a CAGR of around 5.0% over the forecast period (2023-2030).
• In terms of revenue, the global Ultrasonic Welding Systems market size was valued at around USD 560 million in 2022 and is projected to reach USD 827 million, by 2030.
• The global Ultrasonic Welding Systems market is expected to be driven by several factors such as the increasing automotive and electronics sector.
• Based on the type, the plastic ultrasonic welder is expected to hold a significant market share over the forecast.
• Based on the application, the automotive segment is expected to grow at the highest CAGR during the forecast period.
• Based on region, the Asia Pacific is expected to grow at the highest CAGR over the forecast period.

Ultrasonic Welding Systems Market: Growth Drivers

The increasing automotive sector drives market growth

Ultrasonic welding systems have found extensive applications within the automotive industry due to their ability to provide reliable and efficient joining solutions for various materials used in automotive manufacturing. The application of ultrasonic welding in vehicles is in plastic component assembly, exterior components, electrical & electronics components, and air intake & filtration systems. Thus, the ultrasonic welding system market demand is driven by the growing automotive industry. For instance, according to the Society of Indian Automobile Manufacturers, from 30,69,523 to 38,90,114 units were sold overall as passenger vehicles. In FY-2022–23, sales of Passenger Cars climbed from 14,67,039 to 17,47,376, Utility Vehicles from 14,89,219 to 20,03,718, and Vans from 1,13,265 to 1,39,020 units, all compared to the prior year. Furthermore, from 7,16,566 to 9,62,468 units were sold overall in the commercial vehicle category. In FY-2022–23, sales of Light Commercial Vehicles climbed from 4,75,989 to 6,03,465 units while those of Medium and Heavy Commercial Vehicles increased from 2,40,577 to 3,59,003 units compared to the prior year.

Ultrasonic Welding Systems Market: Restraints

Material compatibility acting as a major restraint to the market growth

Only materials that can transmit ultrasonic vibrations may be joined using ultrasonic welding, which is very effective for connecting polymers and some metals. Certain businesses may be unable to employ this technique because some sophisticated materials and composites may not be appropriate. Therefore, material compatibility is expected to be a major restraining factor for the ultrasonic welding system industry over the projection period.

Ultrasonic Welding Systems Market: Opportunities

Growing product launches offer a lucrative opportunity for market growth

The growing product launches are expected to offer a lucrative opportunity for global ultrasonic welding systems market growth during the forecast period. For instance, in January 2022, Emerson unveiled a brand-new ultrasonic metal welder for connecting wire terminations, conductors, and bigger batteries. For the larger welds needed by electric vehicles, batteries, and energy storage systems, Emerson's new BransonTM GMX-HP ultrasonic metal welder combines increased power and downforce with a modular equipment design and features that make installation and automation for machine builders and manufacturers easier. Increased weld power is provided by a large 8-kilowatt, 20-kilohertz power supply in the new GMX-HP. A direct-press actuator that transmits welding power and has precise distance sensors, twin linear bearing guides, and a dynamic pressure trigger provides more part-holding downforce and the high stability required for consistent weld quality. Thereby, driving the market growth.

Ultrasonic Welding Systems Market: Challenges

Limited thickness and complex joint designs pose a major challenge to market growth

The best materials for ultrasonic welding are those that are thin to medium thick. Heavy-duty applications are limited by the challenge and the need for specialist equipment associated with welding very thick materials. Additionally, even though ultrasonic welding is adaptable, it might not be appropriate for excessively intricate joint designs or inaccessible places. Alternative welding techniques or human work may be necessary in such circumstances. Thus, this is expected to pose a major challenge to the market growth.

Ultrasonic Welding Systems Market: Segmentation

The global Ultrasonic Welding Systems industry is segmented based on type, application, and region.

Based on the type, the global ultrasonic welding systems market is bifurcated into plastic ultrasonic welders and metal ultrasonic welders. The plastic ultrasonic welder is expected to hold a significant market share over the forecast period due to the versatility and efficiency of ultrasonic welding in joining plastic materials. In addition, the plastic ultrasonic welder has a wide range of applications in various industries including automotive, electronics, medical, and others. In the automotive sector, these systems are extensively utilized for assembling interior and exterior components, such as dashboard assemblies, door panels, bumpers, and headlamp assemblies. Moreover, in the electronics industry, plastic ultrasonic welders are used for bonding plastic components, connectors, and enclosures in the production of consumer electronics, medical devices, and others. Thus, this is expected to drive the segment growth during the forecast period.

Based on the application, the global Ultrasonic Welding Systems industry is bifurcated into automotive, electronics & battery, medical, packaging, and others. The automotive segment is expected to grow at the highest CAGR during the forecast period. The growth in the segment is attributed to the growing demand for electric vehicles across the globe and the increasing regulation of lightweight vehicles. For instance, according to the International Energy Agency, sales of EVs increased from about 1 million to over 10 million in just five years, from 2017 to 2022. Sales of electric cars, such as battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs), surpassed 10 million last year, an increase of 55% from 2021. In 2022, there will be 10 million EV sales globally, which is more than the 9.5 million automobiles sold in the whole European Union and almost half as many as will be sold in China. Therefore, the aforementioned facts drive the segment growth.

Ultrasonic Welding Systems Market: Report Scope

Ultrasonic Welding Systems Market: Regional Analysis

Asia Pacific is expected to grow at the highest CAGR during the projection period

The Asia Pacific is expected to grow at the highest CAGR in the global ultrasonic welding systems market during the forecast period. The growth in the region is attributed to the robust manufacturing base across the industry including automotive, electronics, consumer goods, and others. The growth in the region is especially driven by countries like China, Japan, India, South Korea, and Taiwan. For instance, the APAC region is a major hub for automotive manufacturing. Ultrasonic welding systems find extensive use in assembling plastic components in automobiles, contributing to the growth of the market.

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For instance, since 2009, China has continued to be the world's largest producer of automobiles and automotive market. China produced more vehicles annually than the European Union, the United States, and Japan, combined, or more than 32 percent of all vehicles produced globally. Furthermore, the electronics industry in the region is booming, which in turn, drives the market growth. According to the figure by Invest India, by FY26, India's domestic electronics manufacturing is anticipated to surpass $300 Billion. India's domestic output now has a CAGR of 15%, rising from $43 billion in FY17 to $87 billion in FY22. Furthermore, it is anticipated that by FY26, the nation's exports of electronics will total $ 120 Bn. With a CAGR of 22%, India's exports of electronic goods climbed from $5 billion in FY17 to $15 billion in FY22. Therefore, the aforementioned stats drive the market growth in the region.

Ultrasonic Welding Systems Market: Competitive Analysis

The global Ultrasonic Welding Systems market is dominated by players like:

• Creast Group
• Branson (Emerson)
• Dukane
• Telsonic AG
• Schunk Group
• Herrmann
• Weihai KAER Ultrasonic Engineering Co. Ltd.
• Shanghai Chenfeng
• SEDECO
• Sonics & Materials Inc.
• SONOTRONIC Nagel GmbH
• Kepu
• K-Sonic
• Xin Dongli
• Nippon Avionics
• Topstar GmbH
• Ever Green Ultrasonic
• Hornwell
• Sonobond

The global Ultrasonic Welding Systems market is segmented as follows:

By Type

• Plastic Ultrasonic Welder
• Metal Ultrasonic Welder

By Application

• Automotive
• Electronics and Battery
• Medical
• Packaging
• Others

By Region

• North America
  • The U.S.
  • Canada
• Europe
  • France 
  • The UK
  • Spain
  • Germany
  • Italy
  • Rest of Europe
• Asia Pacific
  • China
  • Japan
  • India
  • South Korea
  • Southeast Asia
  • Rest of Asia Pacific
• Latin America
  • Brazil
  • Mexico
  • Rest of Latin America
• Middle East & Africa
  • GCC
  • South Africa
  • Rest of Middle East & Africa