Differential technologies
Ultrasonic manufacturing technologies
Eurecat Ultrasonic Moulding: high-precision solutions for developing and industrialising microparts and microcomponents beyond the limits of conventional microinjection moulding
Miniaturisation requires new manufacturing solutions capable of achieving increasingly high levels of precision while using resources efficiently.
Ultrasonic Moulding (USM) represents an innovative alternative to conventional microinjection processes, enabling the production of complex microcomponents and microparts with high precision, greater repeatability and lower energy consumption.
At Eurecat, we support companies throughout the entire process, from feasibility studies to part development, pre-series production, equipment implementation and technology adoption, facilitating the industrialisation of new applications and geometries.
The challenge
Each method offers specific benefits depending on the material, design complexity, and production scale. In particular, micro-injection molding is one of the most widely used technologies for micropart production, as it provides exceptional precision, repeatability, and efficiency.
However, conventional injection molding presents several drawbacks: high energy consumption, excessive material use, waste generation, limited feasibility, etc., especially when producing very small parts weighing between 0.1 g and 1.5 g or with diameters of 0.250 mm.
The use of ultrasonic manufacturing technologies represents a paradigm shift in terms of precision, speed, and energy consumption.
Eurecat’s strategy
We eliminate design and process constraints in the manufacturing of microparts and microcomponents through a flexible approach, starting with feasibility studies or proof-of-concept tests to ensure efficient and successful industrialization of new products.
Experience and competitive results
More than 20 years of experience in ultrasonic micro-injection molding processes and the development of various patents position Eurecat as the most competitive and suitable partner to tackle new challenges in ultrasonic manufacturing.
Eurecat, your strategic partner in micromoulding
20 years leading innovation in Ultrasonic Moulding (USM)
Pioneers in ultrasonic manufacturing (USM) since 2005, Eurecat combines in-house expertise, patents, and a renewed second-generation platform to reduce risks and industrialize new micro-molding applications.
Our flexible, results-oriented model (from proof of concept to industrial scale-up) makes us a true plug-and-play partner for high value-added sectors.
We address both product and process challenges throughout the entire innovation cycle (concept, feasibility, development, and industrialization), leveraging ultrasonic molding to enhance precision, sustainability, and productivity.
1
Development of new processes
Conceptualization, design, proof of concept (PoC), and industrialization.
2
Process improvement with ultrasonics
Molding, overmolding, joining, and extrusion.
3
Product and part development
From concept to manufacturing feasibility for high-precision parts.
4
Technical and economic feasibility studies
Parameter optimization and risk reduction.
5
Plug-and-play solutions
Solutions focused on adjustability, multi-material capability, precision, and productivity, minimizing purging and the consumption of energy and materials.
6
Material testing and characterization
(e.g., COC, PP, POM, PEEK, PLA)
Eurecat, your R&D&I partner in Ultrasonic Moulding
Ultrasonic Moulding (USM) replaces the heating generated by electrical resistances, pressure and shear in conventional systems with a process based on the intermolecular friction of materials exposed to ultrasound. By melting shot by shot and plasticising the material inside the mould, USM enables thinner walls, extreme aspect ratios and greater consistency. The result is faster development, less waste and lower energy consumption for high-precision micro and small parts.
Leading acceleration
A systematic and flexible approach that delivers differential value to our strategic partners.
Highly disruptive
Starting with a proof of concept (PoC) to reduce technological risks and focusing on impact.
Unique value
Covering the entire innovation cycle, from the concept of new microparts or micromoulding processes to industrialization.
Risk mitigation
With a multi-sector and multi-technology approach, combining USM to deliver the best solution.
Make the impossible possible with Eurecat: transform micro-scale challenges into production-ready parts with efficient, low-pressure ultrasonic molding.