A welding system that can remove heat, consumables, and process complexity, enabling cleaner manufacturing and evolving power module designs.
Kulicke & Soffa has introduced ASTERION-TW, an ultrasonic terminal welding system designed for next generation power module manufacturing. The system brings solid-state ultrasonic welding as an alternative to conventional mass-reflow processes, targeting high-reliability applications across renewable energy, transportation, and data center infrastructure.
The system delivers clear benefits at the manufacturing level by eliminating external heat, adhesives, and chemical byproducts. This enables lower energy consumption, zero emissions, and improved recyclability, aligning with green manufacturing goals. By simplifying the bonding process and reducing dependencies on consumables, it also supports more efficient and sustainable high-volume production environments.
At the design level, the system improves process robustness and flexibility. Its ultrasonic bonding approach reduces sensitivity to material tolerances while ensuring consistent weld quality through controlled force application. The system supports evolving power module architectures with greater adaptability, while replacing multi-step thermal processes with a more precise and low-waste alternative.
From a technical standpoint, the system enables bonding of copper terminals up to 2 mm thick using high power and high force capability. A linear motor positioning system delivers ±40 microns weld placement repeatability. Additional features include ±180 degree weld head rotation, a 150 mm vertical stroke for deep cavity access, and a 300 mm by 300 mm work area. An optional inline pallet conveyor with high-force clamping and integrated cleaning further enhances automation and throughput.
“ASTERION-TW reflects our commitment to deliver high performance interconnect solutions through engineering excellence and close collaboration with our customers,” says Ivy Qin, General Manager of Ball and Wedge Bonding at Kulicke & Soffa. “By combining deep process expertise with market-driven innovation, we are dedicated to advancing our customers’ capabilities.”
Click here for the official announcement.
