Ultrasonic milling is an advanced subtractive fabrication technique that superimposes high‑frequency ultrasonic vibrations onto a rotating cutting tool to dramatically improve the machining of hard, brittle, and advanced materials. By oscillating the tool at amplitudes up to approximately 15 µm, the process reduces cutting forces by up to 50%, enabling faster feed rates, improved surface quality, and significantly lower tool wear.

This hybrid approach is particularly effective for materials that are prone to cracking or chipping under conventional milling, including ceramics, glass, corundum, carbides, and fibre‑reinforced composites. Ultrasonic machining also minimises sub‑surface damage, reducing downstream polishing requirements and enabling the fabrication of high‑precision components for optics, photonics, micro‑mechanical systems, and semiconductor applications.