Ultrasonic machining is a low material removal rate (MRR), loose abrasive machining process in which the mirror image of a shaped tool can be created in hard, brittle materials. Material removal is achieved by the direct and indirect hammering of abrasive particles against a workpiece by means of an ultrasonically vibrating tool.

• A nearly limitless number of feature shapes—including round, square, and odd-shaped thru-holes, and cavities of varying depths, as well as OD-ID features—can be machined with high quality and consistency.

• Features ranging in size from 0.008" up to several inches are possible in small workpieces, wafers, larger substrates, and material blanks.

• Aspect ratios as high as 25-to-1 are possible, depending on the material type and feature size. View the ultrasonic machining 3D animation to learn more about how ultrasonic machining works.