STAPLA uses solid horns for the following advantages:

• Significant tool life as opposed to a replaceable tip. This is due to faster heat dissipation in the solid horn.
• The solid horns tune much better to the working frequency under the load and therefore, the energy is much more efficient.
• The solid horn allows assembly of the entire transducer with maximum ngidity and therefore, larger welds can be made accordingly. Furthermore, due to the solid horn efficiency, lower amplitude setting can be achieved to weld small wire such as 22 gauge.
• It is the solid horn design that allows better ergonomics by a flat surface for the hand rest as well as easy access to the welding area.
• The set up of the solid horn as opposed to a rotating tip is much simpler and less susceptive to set up errors.
• The solid horn’s shape lends itself to a much better and effective way of mounting it at the Nodal: area. This eliminates using oscillating discs, which is a very old technology and breaks often.
• Using a high-speed camera, one observes that the solid horn’s vibration is controlled In a longitudinal direction. The replaceable tips show vibration in all directions.

Costs:
Development of special coatings for our tooling has increased tool life and exceeds the tip life expectancy even more now. Our field reports show our horns last five times longer than replaceable tip horns.
The above advantages make the solid horn design a less expensive investment than the replaceable tip design. STAPLA's commitment to excellence and superior technology has provided us with a solid horn design.

Solid Horn vs. Replaceable Tips