Due to a wide and rapid spread of Covid-19 virus, the world exposure suffering from the severe shortage not only for those personal protective equipment that are normally used in hospitals but also extended to the care homes, and because the global rollout of the harmful virus around the world, the number of cases of for pandemic covid-19 is rapidly increased in most countries. The motivation of the current work provide a design of an efficient tools that can overcome many issues concerned with the distribution of virus, and therefore to suppress the prevalence of virus through apply the health rules for quarantine and safety. Ultrasound power technique in general, specifically ultrasonic power remains one of the efficient and reliable processes that can be performed in a wide range of applications such as medical, engineering and manufacturing, which it entered directly in processing different kinds of medicals stuff such as manufacturing medical masks and other accessories beside their other applications in most engineering and industrial fields, etc. The advantage of this technique is crucial and essential in produce protect things required for general purposes like medical masks and their supplements. Design an efficient tool that can be works on the principle of ultrasonic power with providing high performance through add slots will directly leads to enhance many criteria which are benefit in producing large numbers of medical accessories such as facial masks with consuming minimum  amount of materials, cost and time. This work presents a study based on design a wide block horn have double slots and an exponential stepped profile, which the horn is modelled, analysed, fabricated based on selecting of aluminium type 7075 as horn materials and their vibration characteristics such as natural frequency and displacement are successfully extracted, using finite element model. A correlation between the design variables and characteristics of the proposed block horn is obtained through perform sensitivity analysis and investigation of the horn response surface. The simulation program of commercial code ANSYS was performed successfully to characterize the mode shapes of the selected horn models and their data discussion was confirmed experimentally using Doppler effect of 3D laser vibrometer to extract horn measurements. The correlation between electrical impedance and experimental analysis were successfully identified with minimum percentage recoded a value of 2 % varied from the natural frequency of vibrating horn. Optimizing slots position of the designing block horn have been led to significant enough frequency separation measured accordingly to the exciting axial mode with sufficient uniformity of displacement amplitude and minimum stress identified far away from the horn tip; this is recommended in the field of mass production to allow sufficient ultrasonic energy transferred to the working area. This work concludes that designing an efficient horn will surely reflect on works in acceptable quantity and quality processing parts such as in producing medical masks and their supplements. In comparison with traditional processes, performing ultrasonic power results in fewer additives attain joints material with no holes from sewing, or weak strands, revoke the rise of adhesive cost and lower the glue delivery system. In contrast, the ultrasonic process has pace cycle rate which has capability in reducing of maintenance down time.