A Fully Controlled Micro Resistance Welding System for Consistent, Repeatable Results

The Aeon HF Inverter is a high-frequency inverter-based resistance welding system designed for precision micro welding applications.

Take full control of your welding process. The Aeon HF Inverter transforms resistance welding from a variable, trial-and-error process into a measured, controlled, and repeatable system. It is best suited for applications that require tight process control, repeatability, and consistent weld quality in production or automated resistance welding environments.

At its core, the system combines closed-loop feedback with real-time adjustment, built-in force and displacement monitoring, and a design optimized for production and automation.

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What Is a Micro Resistance Welding System?

A micro resistance welding system is a precision welding solution that uses controlled electrical resistance, force, and timing to join small or delicate metal components. These systems are commonly used in applications such as battery tab welding, fine wire welding, and microelectronics manufacturing, where consistency and process control are critical.

Applications for Micro Resistance Welding

The Aeon HF Inverter is designed for micro resistance welding applications where precision, consistency, and control matter most.

Common applications include high production and automated resistance welding systems, microelectronics and precision components, fine wire welding (micro resistance welding applications), thin foil welding, battery tab welding, and dissimilar metal joining.

It works across all metals—including exotic and dissimilar combinations—especially in situations where traditional resistance welding systems struggle with consistency.

From Inconsistent Resistance Welds to a Controlled Process

In traditional resistance welding systems, results are often inconsistent and difficult to control. Compared to these systems, inverter-based platforms like the Aeon HF provide faster response times and more precise control over weld energy and process variables.

Before using the Aeon, common challenges include inconsistent welds, sensitivity to small variations, heavy reliance on operator tuning, and high levels of scrap, defects, and rework.

With the Aeon HF, those challenges are replaced by a controlled and repeatable process:

Weld settings can be dialed in with precision

The system automatically adjusts to part variation

Every weld matches defined parameters

Consistent results are maintained, even in fast, changing conditions

The system measures and adjusts weld output 24,000 times per second, ensuring every weld follows the exact profile required.

Common Resistance Welding Problems It Solves

Many resistance welding processes suffer from variability and instability. The Aeon HF is built specifically to eliminate weld explosions, weak or breaking welds, part defects and mis-welds, and instability caused by material variation.

Instead of relying on trial-and-error, the system delivers a controlled and measurable process with full welding process control.

Total Control Over Your Resistance Welding Process

The Aeon HF brings together monitoring, feedback, and automation to give you control over every critical variable in the resistance welding process.

Closed-Loop Feedback for Resistance Welding

The system continuously monitors weld output and adjusts in real time, maintaining consistent resistance welding performance even when material conditions, resistance, or environmental factors change. This eliminates variability and stabilizes the process.

Force Monitoring and Control

Force is one of the most critical—and often overlooked—variables in resistance welding. The Aeon includes built-in force feedback, ensuring consistent mechanical conditions for every weld without requiring additional equipment.

Displacement Monitoring (with compatible weld head)

Displacement monitoring allows you to measure and control how much material actually melts, enabling you to track melt as a measurable distance and ensure every weld reaches the same condition.

Weld to Displacement Feature

This feature automatically stops the weld when a defined melt point is reached, preventing over- or under-welding and ensuring repeatable weld formation.

Production-Ready Resistance Welding System

The Aeon HF is designed to move seamlessly from development into full-scale production. Built for both engineering and manufacturing environments, it supports high-duty-cycle operation and integrates into automated resistance welding systems.

Key production advantages include:

High duty cycle with advanced heat dissipation

Operation that runs longer and cooler

A design suited for harsh industrial environments

The system is used across R&D labs, production lines, automated systems, and industrial environments.

Advanced Interface and Real-Time Feedback

10” Touchscreen HMI

The integrated 10” touchscreen HMI provides centralized control over the weld process. Operators can configure parameters, monitor performance, and analyze results in real time through graphical feedback and waveform visualization.

The interface includes fully programmable weld settings, live graphical weld feedback, real-time waveform visualization for resistance welding performance analysis, and graphical good/bad weld indicators.

Data Logging and Traceability

Every weld is measured, tracked, and validated, providing full visibility into the process. The system supports pass/fail tracking, exportable weld data, waveform envelope monitoring, and SPC-ready data insights for process control.

Automation and Integration Ready

The Aeon HF integrates into automated resistance welding systems and existing production workflows with support for PLC integration, Ethernet connectivity, remote weld schedule selection, full I/O support, and RS-232 and RS-485 communication.

Key Capabilities

The Aeon HF delivers high-performance welding with an output feedback response time of 40 µs, more than 1,000 programmable weld schedules, a current range of 200A to 2500A, power output up to 6.25 kW, and multi-stage programmable weld pulse control.

It also continuously monitors and controls:

Current

Voltage

Power

Resistance

Time

Energy

Resistance Welding Is More Than Just Energy

Most problems in resistance welding come from oversimplifying the process. True weld quality depends on controlling multiple variables, including force, resistance, energy, time, surface condition, and material variation.

The Aeon HF allows you to measure, monitor, and control all of these variables within a single precision resistance welding system.

Why Choose the Aeon HF Inverter?

No Compromise Control

The Aeon HF delivers full control over the welding process, providing all the capabilities required in a precision resistance welding system.

Don’t Outgrow Your Welder

The system is designed to scale with your needs, allowing you to move from development to production without upgrading equipment.

Consistent Results You Can Trust

The Aeon prioritizes strength, consistency, and appearance—delivering all three reliably.

Visual Proof of Performance

(Section for images and video)

The system demonstrates consistent performance through repeatable weld results, waveform consistency on the HMI, and validated weld samples and cross sections.

Support That Ensures Success

You’re not left to figure it out alone. The Aeon HF is supported by application engineering support, weld testing and validation, training and setup assistance, and process development guidance.

Frequently Asked Questions About Resistance Welding

What is resistance welding used for?

Resistance welding is used to join metal components by applying pressure and electrical current. It is commonly used in applications such as battery tab welding, microelectronics, and fine wire welding.

How does resistance welding compare to laser welding?

Resistance welding uses electrical resistance and pressure to create a weld, while laser welding uses a focused beam of light. Resistance welding is often better suited for high-speed production and repeatable process control.

Why are resistance welds inconsistent?

Resistance weld inconsistency is typically caused by variations in material, surface condition, force, or energy input. Systems with closed-loop feedback and process control help eliminate this variability.

Can resistance welding be used for small or delicate parts?

Yes. Micro resistance welding systems are specifically designed for precision applications such as fine wires, thin foils, and small components where control and consistency are critical.

Not Sure If This Is the Right System?

If your application requires high consistency, process control, and reliable production results, the Aeon HF is likely the right solution.

For simpler or lower-volume welding applications where advanced control and monitoring are not required, other welding systems may be more appropriate.

If you’re unsure, we’ll help you determine exactly what you need.

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