In ultrasonic object consolidation, the location of the sonotrode may be independent, and selected (like other processing parameters such as amplitude, frequency, force, and speed), for optimum processing. According to one preferred embodiment, the improvement includes welding certain regions of the object multiple times. Alternatively or in conjunction with other steps, the method includes the act of selecting sonotrode position to minimize bulk motion of the object. The invention improves upon the existing art by optimizing the positioning of the sonotrode relative to the geometry. This may, for example, comprise independently positioning the horn to treat one or more features within a cross section of the object differently, or determining tape placement location and tacking the feedstock in advance of welding. The feedstock may be provided in any suitable form, including wires, tapes and dots.