Sunstone Wave AC Resistance Welder | Seam & Foil Welding

The Sunstone Wave AC: Up to 2,700 Amperes of Digitally Controlled AC Resistance Welding for Seam, Foil, and Continuous Weld Applications

When your application demands a continuous, uninterrupted weld — not a series of discrete spot welds — the Wave AC is the right tool. Built on a redesigned transformer and fully digital control architecture, it delivers the most precise, visualizable AC resistance welding experience available in a benchtop form factor.

AC Resistance Welding — and Why It's Different

Capacitive discharge and DC resistance welders fire discrete pulses — each trigger actuation produces one weld event. AC resistance welding works differently. The Wave AC flows energy continuously for as long as the trigger is held, making it the correct technology for applications that require a seam rather than a spot.

The AC power supply drives current through a transformer, which delivers a sustained, controlled flow of weld energy to the electrodes. Paired with a roller electrode, this continuous energy flow produces a running seam weld as the electrode travels across the surface — bonding every point of contact along the weld path rather than a series of individual nuggets.

This is what makes the Wave AC the right choice for hermetic sealing, foil pouches, mesh and screen welding, and filter assembly — applications where gaps between spot welds simply aren't acceptable.

A Redesigned Transformer and Digital Control Architecture

The Wave AC is not an incremental update to an older AC welder platform. Sunstone redesigned the transformer and supporting circuitry from the ground up using current-generation electronic components, then paired that hardware with full digital control through a 10-inch color touchscreen.

The result is a level of energy precision that conventional AC welders — built on analog control and legacy transformer designs — cannot match. Energy delivery is more tightly controlled, weld-to-weld variation is reduced, and the operator has complete visibility into every parameter from a single interface.

The Wave AC delivers:

• 225A to 2,700A output current range
• 0.13 kVA to 5 kVA output power range
• Percent phase adjustment from 40–100% for fine-grain energy control
• Single cycle and repeat cycle modes for spot and continuous seam operation
• Half cycle mode for the most delicate, heat-sensitive materials
• Seam mode for continuous weld applications with roller electrodes
• Up to 100 saved weld schedules — store parameters for every recurring application

Waveform Visualization You Can Actually Use

Most resistance welders show you numbers. The Wave AC shows you the shape of your weld.

The 10-inch touchscreen displays every welding parameter as a live waveform — a real-time visual representation of how energy will be delivered to the workpiece. As you adjust power level, phase percentage, cycle count, or timing, the waveform updates immediately. You can see the effect of every change before you make a weld.

This is not a cosmetic feature. For operators setting up a new application — or dialing in parameters for a sensitive material — being able to visualize the energy envelope eliminates the trial-and-error that costs time and material. Set it, see it, weld it. Save the schedule and recall it instantly for the next run.

What the Wave AC Is Used For

The Wave AC's continuous energy delivery and seam mode make it the correct tool for a specific and important category of applications:

Pouch cell welding — hermetically sealing the foil envelope of a lithium pouch cell requires a continuous, gas-tight seam. A spot welder cannot achieve this. The Wave AC, paired with a roller electrode, runs a sealed seam around the perimeter of the pouch in a single pass.

Foil welding and hermetic sealing — any application requiring an airtight or liquid-tight seal on thin foil material. Medical packaging, sensor housings, custom pouches, and protective enclosures for sensitive components.

Mesh and screen welding — bonding every wire intersection in a metal mesh to a substrate, or welding mesh to a frame, requires continuous energy to ensure no gaps. The Wave AC welds every contact point as the electrode travels, producing a uniform, high-strength bond across the entire mesh area.

Filter assembly — filter bodies, baskets, and screen-to-housing attachments in industrial, automotive, and medical filtration components.

Continuous seam welds — any application requiring a linear or contoured weld path rather than discrete spot welds, including aerospace insulation blankets, automotive components, and medical device enclosures.

Weld Modes — Choosing the Right Configuration

The Wave AC supports multiple weld modes, selectable from the touchscreen interface:

Spot mode (single cycle) — one cycle of AC energy per trigger actuation. Used when individual spot welds are required, or when setting up and validating parameters before running a seam.

Repeat cycle mode — the machine fires a set number of cycles per trigger actuation. Used for controlled multi-cycle spot welds or defined-length seam segments.

Seam mode — energy flows continuously while the trigger is held. The correct mode for hermetic sealing, foil welding, and all rolling electrode seam weld applications.

Half cycle mode — delivers only a half cycle of AC energy for extremely delicate materials where even a full cycle produces too much heat. Used for the finest, most heat-sensitive foils and thin-gauge materials at the lower end of the material thickness range.

Choosing Your Power Level: Power Steps 1–4

The Wave AC is a single platform with four selectable power steps (Power Level 1 through 4), each representing a progressively higher output range. Power level is selected through the touchscreen interface — not a hardware switch — so the machine can be reconfigured between applications as needed.

The duty cycle table below shows how maximum duty cycle (the percentage of time the machine can weld continuously) varies by power level and phase setting. Lower power levels support higher sustained duty cycles — meaning longer seam welds or higher-frequency repeat cycles without thermal interruption.

How to use this table to choose your operating parameters:

If your application requires long continuous seam welds at high energy — for example, sealing a large pouch cell perimeter at full power — you'll need to balance your phase setting against the duty cycle limit at your chosen power level to avoid thermal interruption mid-seam. For most foil and mesh welding, operating at Power Level 1 or 2 with moderate phase settings provides the best combination of energy and sustained duty cycle.

If your application is primarily spot welds or short seam segments at lower repetition rates, duty cycle is less of a constraint and you can run at higher power levels and phase settings freely.

Not sure which power level and phase combination is right for your material? Our technical team can help you work through the parameters before you buy.

Full Specifications

⚠ Input Voltage Note: The Wave AC requires a 200–250VAC single-phase power supply. Standard North American 120V outlets are not compatible. A dedicated 208V or 240V circuit is required. If you are unsure about your facility's electrical supply, consult a licensed electrician before purchasing.

👉 Download the Wave AC Data Sheet and Wave AC User's Guide for complete technical specifications and setup instructions.

Why Buy the Wave AC From The Maker's Chest?

75-Day Return Window — more than double Sunstone's 30-day return policy. If the Wave AC isn't the right fit for your application, you have 75 days to return it — giving you time to properly validate the machine in your production environment.

Expert USA-Based Technical Support — AC resistance welding parameter setup involves real application knowledge: phase settings, cycle counts, duty cycle management, and electrode selection. Our team can work through all of it with you.

Dual Lines of Support — access to both our in-house technical team and Sunstone's own resources. Two channels working for you on a single purchase.

Authorized Sunstone Reseller — genuine product, full manufacturer warranty, backed by our additional support layer.

Frequently Asked Questions

What is AC resistance welding and how is it different from CD or DC resistance welding? AC resistance welding uses alternating current from a transformer to deliver welding energy. Unlike capacitive discharge (CD) welders — which store energy in capacitors and release it in a fast, discrete pulse — AC welders flow energy continuously for as long as the trigger is held. This makes AC welding the correct technology for seam welds, foil sealing, and mesh welding, where a continuous, uninterrupted bond is required. CD welders are better suited for discrete spot welds, thermocouple junctions, and fine battery tab welding.

Can the Wave AC make standard spot welds, or is it only for seam welding? Both. The Wave AC supports single-cycle and repeat-cycle spot weld modes in addition to seam mode. However, if discrete spot welds are your primary application — battery tab welding, cross wire welding, thermocouple junctions — a CD welder like the CDDP-A is likely a better fit. The Wave AC's core strengths are continuous seam welding, foil sealing, and mesh welding.

Does the Wave AC require special electrical installation? Yes. The Wave AC requires a 200–250VAC single-phase power supply, which is not the standard 120V household or light commercial circuit. Most manufacturing facilities already have 208V or 240V single-phase circuits available. If yours does not, a licensed electrician will need to install a dedicated circuit before the machine can be used.

What attachments are typically used with the Wave AC? The Wave AC is most commonly paired with a roller hand piece (such as the Sunstone PG2) and a wheel electrode for continuous seam welding. The roller electrode rolls along the surface as the operator guides it, with the Wave AC delivering continuous weld energy through the wheel. For spot weld modes, standard opposed or parallel electrode attachments can also be used.

Can the Wave AC weld pouch cell batteries? Yes — pouch cell sealing is one of the Wave AC's primary applications. The machine's seam mode delivers a continuous hermetic seal around the foil perimeter of the pouch, creating a gas-tight closure that a spot welder cannot replicate.

How many weld schedules can the Wave AC store? The Wave AC stores up to 100 weld schedules. Each schedule saves a complete set of parameters — power level, phase percentage, cycle count, weld mode — for instant recall. This makes job changeovers fast and eliminates re-setup time for recurring applications.

What maintenance does the Wave AC require? Primary maintenance involves regular electrode cleaning and inspection — worn or contaminated electrodes are the most common source of weld quality degradation. Additional maintenance includes monthly cleaning of cooling vents to prevent overheating, quarterly overall inspection, and annual visual and resistive checks of welding cables. The machine's digital control system requires no calibration maintenance under normal operating conditions.

What is your return policy? 75-day returns. If the Wave AC doesn't work for your application, reach out and we'll take care of you.