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When it comes to wire harnesses, cable assemblies or panels, the quality of your electrical connections makes all the difference.
Whether you're supplying electricity to a production line or wiring up a system for automotive or industrial applications, reliable connections are non-negotiable.
Two widely used methods for joining wires are ultrasonic welding and butt crimping. Both are designed to connect wires, but the way they do it - and the results they deliver - are very different.
Let’s start with a quick look at how each process works.
Butt crimps use a metal connector sleeve to join the stripped ends of two wires together, typically in a straight line. A crimping tool is used to compress the sleeve, securing the wires inside.
It’s fast and familiar, especially in settings where simple wire connectors or crimp connectors are needed. However, the strength and conductivity of the joint depend on proper tool calibration, operator skill and the quality of the crimp.
In many industries, this introduces a margin for error, especially when wiring for safety, heat tolerance or vibration resistance.
Ultrasonic welding is a solid-state process that joins materials using high-frequency mechanical vibrations and pressure. It’s commonly used in electrical installations, cable assemblies and electronic systems where precision and consistency are key.
In wiring applications, ultrasonic welding works like this:
The result is a low-resistance, highly conductive joint without solder, adhesives or other consumables. It’s clean, quick and consistent, even across multiple wires.
At Tec-Stop, we support OEM manufacturers and professionals looking for speed, quality, and confidence in their connections - and ultrasonic welding consistently delivers.
Here are 5 reasons why we recommend ultrasonic welding over butt crimps:
Ultrasonic welding creates a true copper-to-copper connection, with:
This reduces electrical resistance, improves current flow and ensures secure connections even under demanding environmental conditions or high temperatures. It’s especially valuable in systems where electrical connectors, push-in connectors or terminal blocks are exposed to power surges or heat cycles.
Ultrasonic welds are solid-state joins that resist fatigue, corrosion, and vibration over time. In contrast, a poor crimp can loosen or degrade, especially in environments with motion or thermal variation.
This makes ultrasonic welding ideal for:
Crimping requires sleeves, tools and manual precision. Ultrasonic welding, once set up, needs only electrical cables, machines, and the proper tooling.
This means:
It also simplifies procurement. Fewer connectors to stock means fewer SKUs to manage - and faster assembly times.
Ultrasonic welds are completed in milliseconds, which is far quicker than manual crimping or soldering. It’s ideal for:
The result is a clean, repeatable, scalable solution that supports both small-run and mass production.
Ultrasonic welding works without external heat, so insulation stays intact and there’s no risk of melting or burn-back.
That means:
It’s a process trusted across consumer electronics, EV battery systems, and power-heavy assemblies where safety and durability are essential.
Crimps still work well for quick, low-voltage projects. But if you need high-performance electrical connections, fault-free production, and confidence in harsh environments, ultrasonic welding is the long-term solution. At Tec-Stop, we stock and support a full range of connectors, equipment, and joining solutions, from plug-and-play cable connectors to custom ultrasonic welders for your production line.
Ultrasonic welding is a technique used to join wires together, specifically copper cable, using high-frequency vibrations and pressure. It’s a fast, clean process that offers a reliable alternative to traditional joining methods like soldering, crimping, and the use of cable connectors. Often used within cable assemblies and electrical components, ultrasonic welding delivers consistent, high-performance joins where safety and reliability are critical.
Like any joining method, ultrasonic welding has its limitations. It’s a powerful tool, but not always the right one for every scenario. Here are a few considerations: Workshop-based process Ultrasonic welding requires specialist equipment and controlled conditions, so it’s not suitable for mobile or on-site use. Material compatibility It’s designed for non-ferrous metals like copper and aluminium. If you’re working with mixed or coated materials, it may not be the best fit. Higher material standards Ultrasonic welding works best with clean, high-quality conductors. While this ensures stronger joins, it may require tighter control over cable specifications - which can increase costs. That said, for production environments, high-performance assemblies and safety-critical applications, the advantages often far outweigh these considerations.
The cost of ultrasonic welding depends on a few key factors, including the number of cables, the gauge (thickness) of the wire, and the production setup. But here’s the bottom line: Faster processing, reduced labour costs Ultrasonic welding is highly efficient, with each weld taking milliseconds, so it’s often cheaper overall than butt crimping, especially in production environments. Fewer consumables With no sleeves, solder or adhesive needed, you’re spending less on parts, and rework is rare thanks to the consistency of the process. Typical pricing As a guide, a 1mm² splice typically costs around £0.15, making it a cost-effective choice for high-quality, scalable wiring. If you're comparing options, we can help you break down the costs based on your specific application, and find the most efficient approach for your setup.
Not externally. The process uses mechanical vibrations to generate friction and bond materials without melting. This means no insulation damage, making it safer than traditional heat-based joining methods like soldering.
Panel wiring refers to the layout and connection of electrical connectors, devices, panel mount connectors, and power supply units inside control panels. It includes routing wires and cables, terminating with push-in connectors or crimp connectors, and ensuring all components meet specific requirements for safety and performance.
Four common types include conduit wiring, trunking wiring, lead-sheathed wiring, and surface wiring. These apply across many industries, depending on budget, installation method, and electrical power demands.
Cable connectors are typically used to terminate or extend electrical cables, offering fast, secure ways to connect two or more cable ends. Electrical connectors is a broader term that includes cable connectors but also covers a wide range of components used to join electrical power or signal paths, from plug-in connectors to panel mount options. Choosing the right type depends on the environment, voltage, and overall system design.
Panel wiring isn’t a one-size-fits-all service, and the price can vary significantly depending on the size, complexity, and specific requirements of your system. For us, it’s not about fitting you into a price bracket - it’s about delivering the right solution for your needs and budget. Whether you're after a one-off control panel or a full-scale production run, we’ll work with you to: Optimise for performance and cost Select components from trusted, cost-effective suppliers (we have accounts with most major brands) Build to your specifications, no matter how bespoke With streamlined, repeatable processes and a focus on long-term reliability, we help you get the most value from your investment, without overpaying or compromising on quality. Need a quote or want to explore your options? Just get in touch and we’ll be happy to provide a tailored, no-obligation proposal.
We’ll help you choose the right solution for your power and connection needs.
Tec-Stop Wiring Limited
Unit 87a
Blackpole West Trading Estate
Worcester
WR3 8TJ
