Ultrasonic Wire Welding

Ultrasonic Welding Solutions

Wire-to-Wire Ultrasonic Welding

Ultrasonic welding is a technique used to join two wires using high-frequency ultrasonic vibrations.


These vibrations generate localized frictional heat at the joint interface. The material melts slightly at the contact point. Pressure is applied, and the materials fuse together as they cool and solidify.


This is commonly used in automotive electronics and high-performance applications.

Two female Kato Cable technicians inspecting a wiring board.

Process Control & Engineering Control Services

Process Control

Precision and consistency are at the heart of every custom cable solution. Our Process Control strategies ensure each assembly meets exact specifications, from initial concept to final production. Through rigorous quality checks, standardized procedures, and real-time monitoring, we optimize efficiency while maintaining the highest level of reliability.

Engineering Control

From concept to completion, Engineering Control ensures every design is optimized for functionality, manufacturability, and long-term performance.  Our expert team evaluates form, fit, and function, applies industry best practices and testing protocols, and leverages innovative solutions to deliver high-quality and cost-effective cable and harness assemblies.

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Our Products are Proudly Made in the USA

The Kato Cable Advantage

The Kato Cable Advantage is a holistic approach to looking at the value that you bring to your customers, employees and community. Our customers relate directly to our responsiveness and engineering value, to the investments that we have made into efficiencies and automation, and to the key metrics of industry leading Quality and On Time Delivery. Our employees relate to a sense of inclusion, an appreciation and value to feedback, and the philosophy of making improvements every day. Our community relates to our growth and volunteerism and leadership that we strive for in our region. Together these attributes and values truly deliver the Kato Cable Advantage!

Quality & Reliability

Delivering precision-engineered wire harnesses, cable assemblies, and electro-mechanical assemblies that meet the highest industry standards.

Innovation

Continuously improving processes and technologies to provide cutting-edge solutions for diverse industries.

Customer Commitment

Building strong partnerships through collaboration, responsiveness, and tailored solutions.

Our Certifications

DQS quality management logo.
WHMA-A-620 logo.
cURus UL-Approved logo

Stay Connected with our Blog

Electrician measurements with multimeter testing current electric in control panel.

An Expert Guide to Electrical Control Panel Assembly

September 25, 2025
Learn how electrical control panel assembly ensures safe, reliable performance. Explore best practices and solutions from industry experts at Kato Cable.
close up of different colored wires being used in cable assemblies

Troubleshooting Guide for Cable Assemblies & Wire Harnesses

September 22, 2025
Learn how to troubleshoot cable assemblies and wire harnesses. Discover common issues, proven solutions, and how Kato Cable helps ensure reliability.
Welding machine welding a metal pipe.

The Benefits of Ultrasonic Welding Over Splicing

By Kato Cable • August 20, 2025
Discover why ultrasonic welding outperforms wire splicing in harness manufacturing—delivering stronger, low-resistance, and scalable connections.

Ultrasonic Welding Contact Us

Looking for Support?

Our team is here to help. Whether you’re looking for a custom solution or need support with an existing project, we’re just a message away. Reach out today, and let’s find the right solution for you.