In mechanical operations, a punch press machine is used to rapidly cut and emboss papers. The use of such mechanical equipment enables mass production processes to operate successfully. Punch press machines are typically composed of die steels, which are soft, can be easily processed, facilitates electrical discharge machining processes, and feature high wear resistance. However, in mass production processes, using die steels to cut and emboss papers easily cause burr formation and unclean cuts. To address this problem, the use of ultrasonic knurl roller, which reduces consumable costs, has been introduced and promoted to various industries. Currently, this type of knurling tool is not manufactured in Taiwan; only non-ultrasonic punch press machines are used in Taiwan. Thus, burrs and unclean cuts are frequently observed in products, which increase product defect rate and consumable costs. In this study, machining design and analysis for knurl welding and cutting were conducted by using an ultrasonic machining method. Subsequently, the analysis of variance (ANOVA) was employed to design and establish machining parameters, such as horn shapes, horn materials, and feed speed. Dimension parameters optimal for the study design and feed speeds were determined by using the nominal-the-best characteristics, and experimental tests were then performed. In this study, the test results were similar to those generated based on the nominal-the-best characteristics, indicating that the obtained parameters (i.e., dimensions and feed speeds) were accurate and that the designed prototype can effectively process and manufacture products. In this study, ultrasonic welding and cutting were systematically integrated. The content of this study was divided into two sections for discussion. In the first section, acoustic horns of various brands were introduced; finite element software ANSYS was used to analyse an optimised acoustic horn; and a frequency counter was adopted to measure the frequency of the horn. Next, the simulation and actual measurement results of the optimized horn were compared. Overall, the results were extremely similar, indicating that the numerical values of the simulation and actual measured values were accurate, which enhanced the performance of the horn. The second section describes the experiments conducted using the Taguchi method. Ultrasonic lace sewing machine was used for weld testing, and the Taguchi method was adopted to determine optimal manufacturing parameters. The parameter results were then tested and compared. The ANOVA results revealed that the crucial factors influencing experimental results were knurling pressure and rotational speed, which are also factors that enhance welding efficiency.