ABSTRACT
Ultrasonic Molding (USM) is a relatively new technology specifically designed for the production of mini and micro plastic parts. This technology was first developed in 2002, using high-power ultrasound to melt a small quantity of polymer and shape it inside a mold. Industrial high-power ultrasound waves are created by an acoustic unit, which encompasses the main elements needed to generate and deliver the mechanical vibrations at ultrasonic frequency. A sonotrode (also called ultrasonic horn) is an element that delivers the mechanical energy into the material. This element must be carefully designed to match the resonance frequency of the ultrasonic transducer attached. Nodal point ultrasonic molding configuration changes the placement of the ultrasonic elements in the mold to have a sealed plasticizing chamber. Filling stability has been one of the main drawbacks of the USM process, particularly when dealing with high performance polymers.
