Significantly Reduced Viscosity in Melted Material
Materials melted via ultrasonics exhibit significantly reduced viscosity, allowing the production of thinner walled, flatter, and longer parts than has ever been achievable before using traditional micro molding technologies.
It is not just the use of ultrasonics that reduces fluidity. The new sprue concept in the Ultrasion technology means that it behaves as an energy director as well as part of the ejection system. The energy director orientates the waves in the flow direction, therefore the molten material and waves travel together toward the cavities, reducing the viscosity of the polymer.
It’s all about applying a high intensity mechanical vibration that transmits energy directly into the polymer molecular structure resulting in a very fast and efficient melting “inside-out” rather than “outside-in” which is typically how melting occurs in injection moulding via electric heaters.
In real terms, this particular characteristic of the ultrasonic moulding process means that 15 mm long parts with wall thicknesses of 0.075 mm are easily attainable. Achievable tolerances are as tight as 0.01 mm.