Ultrasonic metal welding (USMW) has become an efficient technique covers a wide range of applications of metals. Because of recent light weight of the parts, an efficient technique like (USMW) has become more applicable, because it considers more accurate, more minimised welding method than before. Welding horn must be designed on satisfying many criteria: vibrate longitudinally at operating frequency, isolated the axial mode from other nearest vibration frequencies, uniformity of vibration amplitude at the working surface and high amplitude of the operating mode. This research presents an approach to the design and simulate of the horn configuration which satisfies these criteria. The simulation and vibration mode shape characterisation of the horn is discussed and the analysis is accomplished using FE-package (ABAQUS), whilst the vibration modes are classified using experimental data from 3D laser Doppler vibrometer measurements. Modal and harmonic analysis are completed successfully to examine the frequency for the welding tuned horn.