Ultrasonic Consolidation of stainless steel structures is being investigated for potential applications. This study investigates the suitability of Stainless Steel 316L annealed (SS316L annealed) as a building material for Ultrasonic Consolidation (UC), including research on Linear Welding Density (LWD) estimation on micrographs of samples. Experiment results are presented that include the effect of UC process parameters on SS316L annealed UC, optimum levels of these parameters, and bond quality of ultrasonically consolidated SS316L annealed structures in terms of LWD. In support to these efforts, a Measurement System Analysis for LWD assessment has been performed, and a new instrument for LWD measurement was developed. This work will determine local maximum LWD UC process parameters for SS316L annealed structures based upon systematic evaluation of sample micrographs.