Aeronaut Automated Ultrasonic Cutting Systems

Aeronaut has been manufacturing flatbed ultrasonic cutters longer than anyone we know. In fact, when we first started taking ultrasonic cutters to trade shows in Europe, fabric manufacturers didn't believe what they were seeing… that you could ultrasonically cut and seal a circle as easily as a straight line.

Most of the ultrasonic cutters that Aeronaut makes are used in cutting materials for window shades, blinds and outdoor awnings. They are fast and efficient production machines, well able to earn their keep.

The other purposes for ultrasonic cutting are more niche applications. For example the multi-layer insulation (MLI) materials used on satellites and spacecraft. There are more window blinds in most city suburbs (probably 90% cut on Aeronaut cutters) than spacecraft.

Ultrasonic cutters are not the cheapest automated cutters to buy or run. Most blind makers will own at least one Aeronaut blade cutter before buying an ultrasonic machine. However if your work needs ultrasonic cut and seal, then these machines do the job in terms of prodtion, finish and profitability.

Single tool ultrasonic cutters

The Elektron B1 Ultra is a single tool ultrasonic cutter. It offers all the features of the more versatile two tool Elektron B2 Ultra, but if your work only needs one ultrasonic tool, then this machine will suit your needs.

Of course the Elektron B1 Ultra is an industrial strength cutter, built to last which takes all the add-ons and accessories like Cyclops machine vision cameras for pattern alignment and registration, inkjet print heads for order numbers and the quick-change bayonet tool holder takes any tool in Aeronaut's bayonet range. 

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Multi-tool ultrasonic cutters

The Elektron B2 Ultra cutting system is an Elektron B2 fitted with two quick-change bayonet mounts and ultrasonic tooling. The machine includes essential technologies like sonotrode cooling, digital pressure control, an ultrasonic specific vacuum table and software optimised for the process.

The Elektron B2 Ultra is a uniquely useful machine combining performance, profitability and ease of use.

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How Ultrasonic Cutting Works

Ultrasonics are used in many applications from medical imaging to cleaning, welding and cutting. Here, we're only looking at ultrasonic cutting of textiles.

An ultrasonic tool consists of three main parts; a generator which outputs a high audio-frequency signal, and incorporated into the tool body, a piezo element which converts that into an oscillating movement and a sonotrode which amplifies the movement. In the frequency used is beyond the spectrum of human hearing, from 20 kHz to 45 kHz.

The elements in the tool body form a tuned system, like a tuning fork, which vibrates in sympathy with the generator's signal.

Ultrasonic cutting of textiles other than composites, is normally done on a hard table surface such as steel, ceramic or glass. Composite cutting is normally done on a soft overlay where the blade penetrates the cutting surface.

The Sonotrode is the part of the tool which does the cutting work and the tip is specially shaped for the intended purpose. Sharper tips are used to cut and rounded tips to seal. Cut and seal tips can do both jobs on some materials.

The sonotrode tip is vibrating at very high frequency. When in contact with many synthetic fabrics, the vibrations cause the material to melt under the sonotrode.

Given the right sonotrode profile, ultrasonic power and speed, a cut and seal will result in the material.

Synthetic fabrics which don't melt easily such as Kevlar may be cut by a combination of the sawing action of a blade shaped sonotrode and simple fatigue breaking of the fibres.

Natural and soft fibres are generally not obvious candidates for ultrasonic cutting because they can be cut by alternative methods and there's not going to be any melting taking place.

Easy to Use

Easy to Own

High Reliability

Contact Aeronaut

Get the facts from the factory direct. If you want advice on automated cutting, an offer on a complete cutting system or to arrange a demonstration, just ask!