Sonotrode

1. A sonotrode comprising:

multiple layers of a material melted to one another to form a structure, the structure providing a base having an attachment feature configured to operatively secure to an ultrasonic converter, the structure includes a shaft extending from the base to a terminal end providing a working surface configured to selectively engage a workpiece;

wherein the structure has multiple shafts that include a first shaft extending from the base to a first terminal end providing a first working surface configured to selectively engage a workpiece, and the multiple shafts include a second shaft extending from the base to a second terminal end providing a second working surface configured to selectively engage the workpiece, the first and second shafts are integrally formed with the base from the multiple layers to provide an unbroken, monolithic construction.

2. The sonotrode of claim 1 , wherein the structure includes an outer surface that is provided by a substantially unmachined surface.

3. The sonotrode of claim 2 , wherein the unmachined surface is at least 50% of an area of the outer surface.

4. The sonotrode of claim 3 , wherein the shaft and base are interconnected by an integral fillet, and the fillet is provided by the unmachined surface.

5. The sonotrode of claim 1 , wherein the base and the first and second shafts are constructed of the same material.

6. The sonotrode of claim 1 , wherein the first shaft has a first length and the second shaft has a second length that is different than the first length.

7. The sonotrode of claim 1 , wherein an internal cavity is substantially enclosed by the multiple layers and arranged interiorly of an exterior surface of the structure.

8. The sonotrode of claim 7 , a cooling passage is provided within the structure and formed in situ within the multiple layers.

9. The sonotrode of claim 8 , wherein the cooling passage includes multiple passageways intersecting one another at non-perpendicular junctions.

10. The sonotrode of claim 9 , wherein the cooling passage is curved and provides an extrados and an intrados at one of the non-perpendicular junctions.

11. The sonotrode of claim 1 , wherein the structure has a density that varies across at least portions of the multiple layers by greater than 0.1%.

12. The sonotrode of claim 1 , wherein the attachment feature is one of a stud and a threaded hole, the attachment feature having an unmachined external surface formed by the multiple layers.

13. The sonotrode of claim 1 , wherein the structure extends in a longitudinal direction from the base to the working surface, the attachment feature provided at a mounting face of the base, the mounting face having a first central point, and the working surface having a second central point, the first and second central points offset relative to one another with respect to the longitudinal direction.

14. The sonotrode of claim 1 , wherein the structure includes an outer surface, and the structure has a fluid attachment provided at the outer surface by the multiple layers, the fluid attachment in fluid communication with an internal fluid passage.

15. The sonotrode of claim 14 , wherein the fluid attachment is a barb configured to connect to a fluid line.

16. The sonotrode of claim 8 , wherein the cooling passage includes a venturi having first and second tapered portions joined at a throat.

17. The sonotrode of claim 16 , wherein the venturi impinges upon a protrusion at a junction between outlet portions of the cooling passage, the outlet portions provided in the neck near the terminal end.

18. The sonotrode of claim 8 , wherein the cooling passage includes an annular passage fluidly connected to multiple secondary passages.

19. A sonotrode comprising:

multiple layers of a material melted to one another to form a structure, the structure providing a base having an attachment feature configured to operatively secure to an ultrasonic converter, the structure includes a neck extending from the base to a terminal end providing a working surface configured to selectively engage a workpiece;

wherein the attachment feature is an integral transition to a booster configured to attenuate a frequency from a ultrasonic converter, the booster, the base and the neck formed from the multiple layers to provide an unbroken, monolithic unitary structure.

20. An ultrasonic welding system comprising:

the ultrasonic converter configured to vibrate at a desired frequency in response to a signal;

the sonotrode of claim 19 , the booster mounted to the ultrasonic converter.

21. A sonotrode comprising:

a structure providing a base having an attachment feature configured to operatively secure to an ultrasonic converter, the structure includes a shaft extending from the base to a terminal end providing a working surface configured to selectively engage a workpiece;

wherein the structure has multiple shafts that include a first shaft extending from the base to a first terminal end providing a first working surface configured to selectively engage a workpiece, and the multiple shafts include a second shaft extending from the base to a second terminal end providing a second working surface configured to selectively engage the workpiece, the first and second shafts are integrally formed with the base to provide an unbroken, monolithic construction.