The World’s Leading Ultrasonic Machining Company

We provide unique machining solutions for hard, brittle, and specialty materials, so your team doesn’t have to compromise its design.

ISO 9001 Certified

AS9100 Certified

IATF 16949 Compliant

ITAR Registered

Traditional Machining Limits Shouldn’t Hold You Back

Now they don’t have to.

What is Ultrasonic Machining?

Ultrasonic machining is a loose abrasive machining process in which the mirror image of a shaped tool can be created in hard, brittle materials. Material removal begins with a vibrating tool. The vibration propels particles at accelerations in excess of 25,000 g’s. These dynamic particles collide with and grind the workpiece on a micro-level.

Advantages of Ultrasonic Machining

Bullen’s Ultrasonic Machining process had many advantages over traditional machining.

The process is non-thermal, non-chemical, and non-electrical, leaving the chemical and physical properties of the workpiece unchanged. This low-stress process translates into high reliability for your critical applications.

Multiple features can be machined at the wafer or substrate level simultaneously, and the process is often the highest quality and lowest cost solution. If there is a better option available for your project, we’ll let you know.

High-aspect ratio thru-vias; 60-to-1 aspect ratios are possible in glass and advanced ceramic.

Unlike many competing laser and abrasive blasting processes, ultrasonic machining is able to provide vertical sidewalls, so you don’t have to compromise on your design.

The process integrates well with semiconductor and MEMS Machined features, and it can be aligned to previously patterned, machined, or etched substrates.





Fortune 50 Companies


Aerospace & Defense Companies


Mems & Microsystem Developers


Medical & Life Sciences Organizations


Semiconductor Equipment Manufacturers

Materials We Machine

We Machine Hard, Brittle & Specialty Materials including:

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Features and Patterns Possible

Bullen can machine a limitless number of different cuts and shapes, including:

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  • Round Holes
  • Rectangular Holes
  • Odd-shaped holes
  • Slots
  • Blind Cuts
  • Cavities
  • OD and ID Work

Features ranging in size from 0.008″ up to several inches are possible in small workpieces, wafers, larger substrates, and material blanks.

Aspect ratios as high as 60-to-1 are possible, depending on the material type and feature size.

Applications for Ultrasonic Machining

Applications for ultrasonic machining include:
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  • Tight-tolerance round thru-holes for semiconductor processing equipment components
  • Micromachined and micro-structured glass wafers for microelectromechanical systems (MEMS) applications
  • Features machined into Ceramic Matrix Composites for Aerospace manufacturing

A Simple Process to Solve Your Complex Engineering Need 

1. Talk To Our Team

Click “talk to our team” to get in touch today via phone, email, or an RFQ. Describe your design, budget, and timeline, and one of our Sales Engineers will get back to you quickly - most of the time, on the same day. If we’re not the right fit, we promise to point you in the right direction.

2. Plan

We leave no stone unturned during our planning process. Bringing in our engineers, R&D team, and technical support staff, we review your design or concept and work with you to understand your unique requirements. In this phase, we often collaborate with clients to reduce product realization times and costs without sacrificing superior quality. We then prepare a project proposal for your review.

3. Prototype & Pilot Production

We know your time is valuable. That’s why your dedicated Sales Engineer will serve as your advocate, ensuring your custom prototype is delivered on time and to your quality standards. We are already evaluating what final production will look like in this phase, applying innovative solutions to ensure future efficiencies and reduced costs.

4. Produce

Congrats - another job well done! It’s time to transform your prototype part into volume production. Did you know that we can custom-build machines and tools for higher-volume clients to drive down your cost? No matter what path we choose, you can rest assured we are working with your best interest in mind and with the same support and quality inspection that got us to this point. Time to check this box and move on to your next challenge!

The Bullen Committment




While we’d love to boast on the fantastic things our clients are doing, we know that your confidence is of utmost importance. You can rest assured that your production and design are always fully confidential.


No hidden fees, no last-minute surprises. When you engage with our team, we promise to be upfront and provide a clear path to your production. If we aren’t the right fit for your project, we’ll point you in the right direction.


Know you’re taken care of every step of the way - from concept to mass production. Our team at Bullen always begins with final production in mind, often custom building machines for our higher-volume clients so they can drive down cost and increase efficiencies.

5 Reasons to Choose Ultrasonic Machining Over Conventional

Stop letting the limitations of traditional machining hold you back. Download this free PDF today.