Ultrasonic units with super fast, very short strokes, provide virtual unrestricted finger tip control. By comparison, regular reciprocating tools—such as air-driven or electric flexible shaft-operated die profilers—are more restrictive in movement and less flexible to handle.
Nevertheless, die profilers and/or various other filing machines are great for medium to large mold details and when used at a comfortable speed range and proper stroke lengths they will provide excellent finishing capabilities.

Ultrasonic polishing is ideal and justifiable when work on small to very small details is required. It is safe to say that the smaller, more intricate or precise the finishing work needs to be, and/or the harder the materials are which require finishing, the more likely it is that an ultrasonic unit will improve polishing time. Subsequently, complicated heat-treated molds and dies, carbide dies or inserts and detailed punches with fine edges and very narrow slots machined by EDM are perfect for using ultrasonic polishing systems.

  It should be mentioned here that there are other advantages that make certain ultrasonic systems a practical purchase. Meaning, various models offer dual operating capabilities where the electronic power module not only has the ability to drive the ultrasonic handpiece, but also regulate the speed and rotational direction for a variety of rotary and/or reciprocating hand tools.

  Having these secondary functions presents additional cost savings over single function ultrasonic units as they permit a full range of filing/reciprocating capabilities as well as rotational grinding/polishing using mounted points, burs, polishing brushes and felt bobs. Furthermore, since the rotary or reciprocating hand tools are powered with internal DC motors, the thin electrical cord provides more freedom of movement when compared to flexible shaft powered tools.              

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