SBT Ultrasonic Partners with TE Connectivity to Drive Mass Production of Aluminum Automotive Wire Harnesses

At the recent electronica 2026, Sbt Ultrasonic (Stock code: 688392) signed a strategic cooperation agreement withTE Connectivity. The partnership is dedicated to jointly overcoming the mass production bottlenecks of "complete copper-to-aluminum substitution" in the automotive sector, while driving the construction and development of an innovative ecosystem.

Driven by the synergy of "dual carbon" targets, automotive lightweighting trends, and the industry’s demand for cost reduction and efficiency gains, weight reduction and copper substitution in wiring harnesses have emerged as core market demands. Compared to traditional copper wiring, ultrasonic welding for aluminum wire faces multiple technical hurdles. SBT Ultrasonic has successfully overcome key bottlenecks—including sonotrode sticking, insufficient welding speeds, and yield control challenges. Launching the integrated ultrasonic welding solution for full-specification (0.5–4 mm²) low-voltage aluminum wire/cables. Seamlessly balancing cycle time, joint reliability, and total production line cost advantages, this solution builds the core technological backbone for the industrialized, high-volume mass production of aluminum wire harnesses.

As a key partner in TE Connectivity's innovation ecosystem, SBT Ultrasonic showcased its Ultrasonic High-Speed Welder for Small-Diameter Aluminum Wire at the exhibition. As the flagship equipment for automated low-voltage aluminum wire processing lines, this machine serves as a direct alternative to traditional crimping processes used for low-voltage copper wire, boasting the following distinct features:

1. Precisely adapt to material properties

• Digital Frequency Ultrasonic System: Equipped with an advanced digital frequency system to optimize precise control mechanisms for micro-energy and micro-pressure.
• Smart Parameter Matching: Automatically adapts welding parameters based on specific wire diameter specifications.
• Flawless Solid-State Bonding: Effectively disrupts the surface oxide film on aluminum wires to achieve a metallurgical-grade solid-state bond, while eliminating defects such as wire breakage and excessive deformation.

2. Optimized for High-Takt Mass Production

Sub-1-Second Weld Time: Keeps individual weld cycles under 1 second, perfectly aligning with the high-velocity takt times of automotive wiring harness mass production.

 3.  Advanced Quality Monitoring & Traceability

Equipped with a built-in, in-line vibration monitoring system, the welder delivers real-time oversight of the welding process, automatically identifying production anomalies such as under-welding, over-welding, and wire misalignment. Furthermore, it logs comprehensive welding statistics, achieving end-to-end data traceability across the entire manufacturing cycle.

4. Minimizing Line Retrofitting Costs

Utilizing a highly integrated and compact design, the welder can be effortlessly deployed into existing automated low-voltage assembly lines. This exceptional adaptability enables wiring harness manufacturers to scale up production with minimal initial capital investment and line modification costs.

This partnership marks a significant step forward in broadening the deployment of Ultrasonic Technology within automotive wiring harness welding, shifting the "aluminum-for-copper" transition from localized validation to full-scale industrial adoption.Moving forward, SBT Ultrasonic will maintain its strategic focus on core ultrasonic innovations. By collaborating with ecosystem partners, we aim to drive the automotive wiring harness industry toward a lighter, lower-carbon future, fueling the high-quality evolution of the global NEV market.