Ultrasonically assisted Plastic Extrusion

MPI offers the industry’s one and only effective solution for ultrasonically assisted extrusion and drawing applications. Our patented MMM ultrasonic generators have the unique ability to apply high power ultrasonic energy to large mechanical systems like extruder heads and drawing dies.

Complete system for ultrasonically-assisted plastic extrusion including computer-controlled generator.

Key benefits to ultrasonic vibrations:

Friction reduction between the tool and the extruded or drawn material, leading to:

  • Improved Material Flow
  • Reduced Pressure
  • Faster Extrusion or Drawing
  • Less breakage in a drawing process improves production yield.
  • Improved surface quality of extruded or drawn material.

In some processes the material structural characteristics may also be improved.

Optional locations for applying ultrasonic vibrations to the plastic extrusion process

The ability to implement such systems in production environments has been restricted due to limitations of conventional ultrasonic technology. Our MMM solution is a breakthrough in this regard and allows us to greatly expand and create new applications.


Compared to conventional ultrasonic technology, MMM offers:

  • Stimulates wideband (sonic to megahertz) acoustic activity throughout the extruder head or die greatly improves the process.
  • MMM eliminates standing waves, the areas of low and high acoustic energy, as seen in fixed frequency systems.
  • MMM technology will effectively drive most any size tool or mechanical systems.
  • Wave-guides connecting the transducer to the tool can be extended up to 3 meters for very high heat environments or unusual applications requiring the transducer to be located away from the working tool.

Range of components for ultrasonically-assisted plastic extrusion using clamp-on ultrasonic system

Aluminum blocks modified by drilling additional holes in the bulk of the aluminum to facilitate multifrequency vibrations. Holes in aluminum blocks can be drilled on many different ways from either side of the block.

Drilling holes in the vibrating aluminum body makes it more flexible and facilitates vibrations, imparting increased amplitude to the central region for the most beneficial effect on the process (plastic flow). Each hole acts as a mass-spring oscillator with relatively high mechanical quality factor. The combined effects of multiple holes generate complex vibrations of the aluminum block.

Clamp-on ultrasonically-assisted plastic extrusion system with water cooling to waveguide

Finding the optimum configuration of holes (size and locations) is a complex process. Testing different geometries in a prototype or production environment is highly recommended.

The converter can be securely fitted on either side of the aluminum block, using a waveguide between the converter and block. Water cooling to the waveguide and air cooling to the transducer will prevent excessive heat transfer from the extrusion process to the converter.

Ultrasonically Assisted Plastic Extrusion - Production prototypes

Ultrasonically agitated plastic extruder in a composite plastics production line
Ultrasonically agitated plastic extruder for composite plastics
Ultrasonically agitated plastic extruder in a composite plastics production line
Extruder in the production line

More information

For more information on MMM ultrasonic machining, drawing, extruding and cutting, including detailed pdf reports and videos, please see our library files on mastersonics.com.