How does it work?

Ultrasonic energy has been used for many years in the injection moulding sector in the form of ultrasonic welding machines. The process is used to weld two room temperature moulded parts together by vibrating the two halves of the join to create frictional heat, enabling a molten polymer weld to be formed between the two parts.

Our Soniplas system uses the same ultrasonic energy, but applies it to the molten polymer as it is injected into the mould, providing a temporary reduction in viscosity as the polymer melt fills the tool. The low power ultrasonic energy is only used to vibrate the molten polymer, with all material heating coming from the barrel heaters. Physical testing of parts moulded with and without ultrasonic flow enhancement validates no change in moulded part physical properties. Similarly, before and after MFI testing also validates no changes to the moulded material properties.

How does it work?

Ultrasonic energy has been used for many years in the injection moulding sector in the form of ultrasonic welding machines. The process is used to weld two room temperature moulded parts together by vibrating the two halves of the join to create frictional heat, enabling a molten polymer weld to be formed between the two parts.

Our Soniplas system uses the same ultrasonic energy, but applies it to the molten polymer as it is injected into the mould, providing a temporary reduction in viscosity as the polymer melt fills the tool. The low power ultrasonic energy is only used to vibrate the molten polymer, with all material heating coming from the barrel heaters. Physical testing of parts moulded with and without ultrasonic flow enhancement validates no change in moulded part physical properties. Similarly, before and after MFI testing also validates no changes to the moulded material properties.

How can you benefit?

The technology can be used in a number of different ways, depending on what the moulder wants to achieve;

Reduced energy consumption and reduced cycle time are often key requirements from our customers. In this case, Soniplas can be used to reduce melt temperatures, by compensating for the increased viscosity that would normally be associated with a melt temperature reduction of, say, 30oC or more. Reduced melt temperatures means less heat to remove after injection, which reduces the cooling time.

For existing, difficult to mould parts with a high scrap rate, the system may be used just to improve part quality and reduce scrap. The flow enhancement reduces the injection pressure required, making the part easier to mould around complex tooling features. In addition, with injection pressure defining the clamp force requirement for a given mould, Soniplas can be used to reduce the clamp force requirement for a given tool.

The technology enhances the flow path to wall thickness ratio for a given polymer. For those designing new parts and tooling, the technology provides an additional design freedom, enabling a down gauging of wall thickness, helping to satisfy those driven by the lightweighting or material saving agenda.

The system operates in a failsafe manner, as tooling can be run both with or without Soniplas switched on.

Material compatibility

Many man-years of development have gone into establishing operating parameters for various different polymers and formulations, without degrading the material. The low energy vibration of the polymer melt enables us to unlock the thixotropic (shear thinning) properties of polymer materials and our intellectual property portfolio for the technology enables us to share this know-how with our customers, to get the very best out of the technology.

The polymer melt is vibrated using transducers mounted within the melt stream, between the nozzle and the tool cavity. With ultrasonic energy being transferred into the melt with transducer amplitudes of just a few microns, the acoustic modelling of each transducer is a critical part of each system build. Each sonotrode and booster system is acoustically modelled to ensure resonance at the correct operating conditions, enabling the system to ‘ring’, just like a tuning fork. Systems are configured to give optimum performance for a range of different settings.

How can you benefit?

The technology can be used in a number of different ways, depending on what the moulder wants to achieve;

Reduced energy consumption and reduced cycle time are often key requirements from our customers. In this case, Soniplas can be used to reduce melt temperatures, by compensating for the increased viscosity that would normally be associated with a melt temperature reduction of, say, 30oC or more. Reduced melt temperatures means less heat to remove after injection, which reduces the cooling time.

For existing, difficult to mould parts with a high scrap rate, the system may be used just to improve part quality and reduce scrap. The flow enhancement reduces the injection pressure required, making the part easier to mould around complex tooling features. In addition, with injection pressure defining the clamp force requirement for a given mould, Soniplas can be used to reduce the clamp force requirement for a given tool.

The technology enhances the flow path to wall thickness ratio for a given polymer. For those designing new parts and tooling, the technology provides an additional design freedom, enabling a down gauging of wall thickness, helping to satisfy those driven by the lightweighting or material saving agenda.

The system operates in a failsafe manner, as tooling can be run both with or without Soniplas switched on.

Material compatibility

Many man-years of development have gone into establishing operating parameters for various different polymers and formulations, without degrading the material. The low energy vibration of the polymer melt enables us to unlock the thixotropic (shear thinning) properties of polymer materials and our intellectual property portfolio for the technology enables us to share this know-how with our customers, to get the very best out of the technology.

The polymer melt is vibrated using transducers mounted within the melt stream, between the nozzle and the tool cavity. With ultrasonic energy being transferred into the melt with transducer amplitudes of just a few microns, the acoustic modelling of each transducer is a critical part of each system build. Each sonotrode and booster system is acoustically modelled to ensure resonance at the correct operating conditions, enabling the system to ‘ring’, just like a tuning fork. Systems are configured to give optimum performance for a range of different settings.

System configuration

Soniplas systems can be supplied in a range of formats to suit the application. Traditional cold runner tools are serviced through our fixed platen mounted system – a range of bolster sizes are available and can be specified by the customer. This format can also be used to run heated sprue bush tooling. We are also able to offer systems for customers to integrate into their own hot runner systems, although this is likely to be more attractive for new build tooling. In a number of cases, our cold runner system can be used to feed an existing hot runner tool.

We can supply the system in a range of power sizes (1.3kW, 2.5kW or 4.0kW), to cater for different materials and shot weights. Where tooling has multiple gates, we can offer a multi-transducer system, providing excitation of the melt just as it enters the tool.

Control system connectivity

Our user interface is presented as a stand alone control plinth, controlling our melt tube temperatures, cooling system settings & alarms, moulding machine injection parameters and ultrasonic power levels & timing. Communication with injection moulding machine is either via a Euromap62 interface, or through a volt free contact.

System configuration

Soniplas systems can be supplied in a range of formats to suit the application. Traditional cold runner tools are serviced through our fixed platen mounted system – a range of bolster sizes are available and can be specified by the customer. This format can also be used to run heated sprue bush tooling. We are also able to offer systems for customers to integrate into their own hot runner systems, although this is likely to be more attractive for new build tooling. In a number of cases, our cold runner system can be used to feed an existing hot runner tool.

We can supply the system in a range of power sizes (1.3kW, 2.5kW or 4.0kW), to cater for different materials and shot weights. Where tooling has multiple gates, we can offer a multi-transducer system, providing excitation of the melt just as it enters the tool.

Control system connectivity

Our user interface is presented as a stand alone control plinth, controlling our melt tube temperatures, cooling system settings & alarms, moulding machine injection parameters and ultrasonic power levels & timing. Communication with injection moulding machine is either via a Euromap62 interface, or through a volt free contact.

Still not convinced?

Different materials respond in different ways, but as an indication of what it can do on real world production parts, here are some results using polypropylene….

Moulding test conditions were as follows:

  1. 15 second cycle time; 230 °C injection temperature; 110 bar injection pressure, 500 kN clamp force – No ultrasonic applied
  2. 12 second cycle time; 180 °C injection temperature; 95 bar injection pressure, 350 kN clamp force – Produced using Soniplas


Soniplas produced a 27% reduction in average power used per shot and a 20% reduction in cycle time.

What could this do for your business?

Still not convinced?

Different materials respond in different ways, but as an indication of what it can do on real world production parts, here are some results using polypropylene….

Moulding test conditions were as follows:

  1. 15 second cycle time; 230 °C injection temperature; 110 bar injection pressure, 500 kN clamp force – No ultrasonic applied
  2. 12 second cycle time; 180 °C injection temperature; 95 bar injection pressure, 350 kN clamp force – Produced using Soniplas


Soniplas produced a 27% reduction in average power used per shot and a 20% reduction in cycle time.

What could this do for your business?

Matrix Moulding Systems Ltd (Matrix)

Matrix Moulding Systems Ltd (Matrix) is a spin-out company from The Technology Research Centre Ltd (TRC) group, who develop new products and processes across a variety of industry sectors, with the main areas of operation in plastics processing, materials recycling & food processing.

Contact Us

Matrix Moulding Systems Ltd (Matrix)

Matrix Moulding Systems Ltd (Matrix) is a spin-out company from The Technology Research Centre Ltd (TRC) group, who develop new products and processes across a variety of industry sectors, with the main areas of operation in plastics processing, materials recycling & food processing.

Contact Us