CNC Ultrasonic Machining
CNC Ultrasonic Machining – Micron-Level Accuracy in Advanced Materials
“Advanced Vibration Technology for Precision Cutting Without Thermal Stress”
5/5
CNC
Years of experience
CNC Ultrasonic Machining: Precision Solutions for Hard and Brittle Materials
What Is CNC Ultrasonic Machining?
CNC ultrasonic machining (USM) is an advanced, high-precision manufacturing process that uses high-frequency ultrasonic vibrations in combination with abrasive slurry to remove material from hard, brittle, or delicate components. Unlike conventional CNC cutting, USM does not rely on mechanical force alone, making it ideal for machining materials that are difficult or impossible to process with traditional methods, such as glass, ceramics, sapphire, quartz, carbides, and advanced composites. This process enables the creation of intricate shapes, micro-holes, and fine features without causing cracks, chipping, or heat-induced deformation.
Key Advantages of CNC Ultrasonic Machining
Crack-Free Machining – Chip-free and stress-free material removal preserves the integrity of brittle components.
No Heat-Affected Zone (HAZ) – The process generates minimal heat, preventing thermal damage and maintaining material properties.
High Dimensional Accuracy – Achieve precise tolerances and repeatable results, suitable for critical applications in aerospace, medical, and electronics.
Capability for Complex Geometries – Easily machine micro-holes, thin walls, sharp edges, and intricate contours that are challenging for conventional CNC methods.
Surface Quality & Finish – Smooth surfaces with minimal post-processing required, suitable for functional and optical components.
Wide Material Compatibility – Works with ceramics, glass, carbides, sapphire, quartz, and other advanced engineering materials.
MW+: Your Trusted CNC Ultrasonic Machining Partner
At MW+, we provide high-precision CNC ultrasonic machining services that meet the most demanding industrial standards. Equipped with advanced USM machines, skilled engineers, and strict quality control protocols, we deliver prototypes and production components with consistent accuracy, superior surface finish, and structural integrity.
Why MW+ Stands Out
ISO-certified quality system with full inspection reports
Expertise in machining brittle and hard materials with minimal defects
Engineering support for design optimization, material selection, and tolerance planning
Seamless transition from prototyping to mass production
Competitive global pricing with fast, reliable lead times
Precision CNC Ultrasonic Machining Services & Solutions
Our ISO 9001 & AS9100 certified CNC ultrasonic machining solutions harness high-frequency vibrations combined with multi-axis CNC control to precision machine complex geometries in ultra-hard and brittle materials. With 15+ years of single-minded experience, we achieve ±0.005mm tolerances and 99.8% first-pass yield rates, impossible by conventional machining.
Certified Ultrasonic Machining Capabilities
- Advanced Material Processing: We’ve successfully finished 5,000+ projects machining advanced ceramics (Al₂O₃, ZrO₂, SiC), glass, and composites with zero thermal distortion.
- Precision Engineering: Our ultrasonic milling and drilling operations have ±0.005mm tolerances on 10,000+ batches of components, with uniform quality for aerospace and medical applications.
- 5-Axis CNC Integration: Our certified processes support intricate 3D geometries and micro-features to 0.1mm, with 40% reduced cycle times compared to traditional methods.
Being a foremost ultrasonic machining supplier with ISO 9001 & AS9100 certification, we promise high-reliability custom ultrasonic machining services for your most challenging applications. Order your ultrasonic machining quote.
20,000+ Precision Parts, 150+ Materials
4.9/5
Tolerance Standard
±0.0005" Precision Guarantee
Since 2015
5/5
Surface Finish
C8-16 μin Ra Mirror Finish
Since 2015
4.8/5
Maximum Workpiece
40" × 28" × 20" Capacity
Since 2015
4.5/5
Material Hardness
Up to 65 HRC Processed
Since 2015
Tolerance for CNC Ultrasonic Machining Services
Limits for nominal size
Metals (ISO 2768- f)
Plastics (ISO 2768- m)
0.5mm* to 3mm
±0.05mm
±0.1mm
Over 3mm to 6mm
±0.05mm
±0.1mm
Over 6mm to 30mm
±0.1mm
±0.2mm
Over 30mm to 120mm
±0.15mm
±0.3mm
Over 120mm to 400mm
±0.2mm
±0.5mm
Over 400mm to 1000mm
±0.4mm
±0.8mm
Over 1000mm to 2000mm
±0.5mm
±1.2mm
| Category | Parameter | Standard Grade | Precision Grade | Validation Method |
|---|---|---|---|---|
| Material Properties | Ultimate Tensile Strength | 450 MPa (Al 6061) | 900 MPa (Ti-6Al-4V) | ASTM E8/E21 Testing |
| Thermal Expansion Coeff. | 23.6 μm/m°C (Al) | 8.6 μm/m°C (Invar) | TMA Analysis | |
| Dimensional Control | Positional Tolerance | ±0.005″ | ±0.0008″ | CMM (0.5μm resolution) |
| Surface Profile | 0.010″ | 0.002″ | Laser Scanning | |
| Process Capabilities | Minimum Feature Size | 0.020″ | 0.005″ | Microscope Measurement |
| Aspect Ratio (Depth/Dia.) | 10:1 | 20:1 | Tool Deflection Analysis | |
| Thermal Management | Operating Temp Range | -40°C to +120°C | -196°C to +350°C | Thermal Cycling Tests |
| Thermal Conductivity | 167 W/mK (Cu) | 400 W/mK (CVD Dia.) | Laser Flash Analysis | |
| Surface Engineering | Ra Surface Roughness | 125 μin | 4 μin | White Light Interferometry |
| Coating Thickness | 25-50 μm | 5-10 μm | XRF Measurement | |
| Dynamic Performance | Fatigue Cycles @ 10^6 | 350 MPa | 550 MPa | Resonant Fatigue Testing |
| Vibration Damping | 0.05 ζ | 0.15 ζ | Modal Analysis | |
| Metrology | Measurement Uncertainty | ±0.0002″ | ±0.00005″ | NIST Traceable Standards |
| Flatness/Parallelism | 0.001″/in | 0.0002″/in | Optical Flats | |
| Environmental | Corrosion Resistance | 500h Salt Spray | 2000h Salt Spray | ASTM B117 Testing |
| Outgassing (TML/CVCM) | <1.0%/0.1% | <0.1%/0.01% | NASA ASTM E595 |
CNC Ultrasonic Machining Surface Finishes
We provide finishes for aesthetics and performance: anodizing, polishing, sandblasting, coatings, and heat treatment. Let’s find the right one!
As Machined
This machined finish is rough and displays tool marks, representing the most basic form of surface treatment without any additional finishing or polishing.
Anodizing
It creates a protective oxide layer on aluminum, increasing corrosion resistance and hardness, and allowing for dyeing to enhance appearance.
Polishing
Polishing smooths surfaces to a high sheen, enhancing appearance and reducing roughness while offering some corrosion protection.
Brushed Finish
A brushed finish has fine, parallel lines for a textured look, enhancing grip and reducing fingerprints.
Sandblasting
Sandblasting uses high-pressure air and abrasive particles to clean or texture surfaces, enhancing adhesion for coatings.
Electropolish
Electropolishing is an electrochemical process that smooths and brightens metal surfaces, removing imperfections and enhancing corrosion resistance.
Engineering Materials for High-Performance Components
Tool Steel (high wear resistance)
D3 is a high carbon, high chromium tool steel known for its excellent wear resistance and ability to maintain a sharp edge. It is commonly used for cutting tools, dies, and industrial applications requiring high durability.
Subtypes:
- D3 (Standard)
- D3 Cold Work Tool Steel
Pre-Hardened Tool Steel
P21 is a pre-hardened tool steel that offers good machinability and wear resistance. It is ideal for making molds and dies, as it doesn’t require extensive heat treatment.
Subtypes:
- P21 (Standard)
- P21+ (Improved)
Hot Work Tool Steel
H11 is a hot work tool steel known for its toughness and thermal fatigue resistance. It is used in applications involving high temperatures, such as die casting and forging.
Subtypes:
- H11 (Standard)
- H11A (Modified for improved toughness)
Polyoxymethylene (Acetal)
POM is a high-performance engineering thermoplastic known for its low friction, high stiffness, and excellent dimensional stability. It’s widely used in precision parts and mechanical components.
Subtypes:
- POM-C (Copolymer)
- POM-H (Homopolymer)
Polyamide (Nylon)
PA is a versatile synthetic polymer known for its high strength, toughness, and excellent chemical and wear resistance, commonly used in textiles, automotive components, and industrial applications.
Subtypes:
- PA(Nylon) Blue
- PA6 (Nylon)+GF15 Black
- PA6 (Nylon)+GF30 Black
- PA66 (Nylon) Beige (Natural)
- PA66 (Nylon) Black
Polypropylene
PP is a lightweight, durable thermoplastic known for its chemical resistance and versatility. It is widely used in packaging, automotive parts, and consumer goods.
Subtypes:
- PP Homopolymer
- PP Copolymer
High-Density Polyethylene
HDPE is a strong and versatile thermoplastic known for its high strength-to-density ratio. It is commonly used in containers, piping, and plastic bottles.
Subtypes:
- HDPE (Standard)
- HDPE (Recycled)
Low-Density Polyethylene
LDPE is a flexible and durable thermoplastic known for its low density and high chemical resistance. It is often used in packaging films and bags.
Subtypes:
- LDPE (Standard)
- LDPE (Recycled)
Polycarbonate
PC is a strong, impact-resistant thermoplastic known for its clarity and heat resistance. It is commonly used in eyewear lenses, safety equipment, and electronic components.
Subtypes:
- PC (Standard)
- PC (Flame Retardant)
High-Impact Polystyrene
HIPS is a tough and impact-resistant thermoplastic known for its ease of processing and good surface finish. It is commonly used in consumer products and packaging.
Subtypes:
- HIPS (Standard)
- HIPS (Recycled)
Polybutylene Terephthalate
PBT is a thermoplastic engineering polymer known for its excellent mechanical properties and chemical resistance. It is often used in automotive and electrical applications.
Subtypes:
- PBT (Standard)
- PBT (Reinforced)
Polyamide-imide
PAI is a high-performance thermoplastic known for its excellent thermal stability and mechanical properties. It is used in high-temperature applications and aerospace components.
Subtypes:
- PAI (Standard)
- PAI (Filled)
High-Speed Steel
M2 is a high-speed steel known for its high hardness, wear resistance, and ability to retain hardness at elevated temperatures. It is commonly used for cutting tools and drills.
Subtypes:
- M2 (Standard)
- M2 (Coated)
High-Speed Steel
HSS is a high-performance tool steel known for its ability to cut at high speeds without losing hardness. It is widely used in manufacturing cutting tools.
Subtypes:
- HSS (Standard)
- HSS (Coated)
Polyether Ether Ketone
PEEK is a high-performance thermoplastic known for its excellent chemical resistance and thermal stability. It is used in specialized applications such as aerospace and medical devices.
Subtypes:
- PEEK (Standard)
- PEEK (Reinforced)
Polymethyl Methacrylate
PMMA is a transparent thermoplastic known for its clarity and UV resistance. It is commonly used as a lightweight alternative to glass in various applications.
Subtypes:
- PMMA (Standard)
- PMMA (Impact Resistant)
Polytetrafluoroethylene (Teflon)
PTFE is a high-performance fluoropolymer known for its non-stick properties and chemical resistance. It is widely used in coatings, seals, and gaskets.
Subtypes:
- PTFE (Standard)
- PTFE (Filled)
