• polystyrene
• polyurethane
• shaping
• sonotrode
• ultrasound

Ultrasound technology can represent a valuable alternative to traditional manufacturing methods of foam-like materials like polyurethane, polystyrene and wax.
Furthermore, other foam-like materials can be machined with the operation method proposed in this study, and this could be an alternative 3D modeling, at least for shaping and simple machining operations. In facts, depending both on the input parameters and on the material type, simple traditional operations like drilling of holes can be performed with encouraging results.
This has been confirmed thanks to dimensional analyses comparison and material analyses. The first ones have been helpful for understanding the quality of the manufacturing process, while the second analyses made possible to understand the physics behind the manufacturing process.
The dimensional analyses revealed that grooving operation performed on Polystyrene and Polyurethane has a good precision level, if considered together with the limitations of the physical properties of materials shaped.
Of particular interest, as regards ultrasound processes, is the absence of dust and debris, which results in a considerable advantage for industries interested in shaping of these types of material.