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I want to make an ultrasonic cutter for home use projects, something like this or there are many online videos of industrial ultrasonic cutters in e.g. the food industry. A typical design of an ultrasonic cutter is below on the left (a). It has a booster (a shaped metal cylinder whose length has been tuned to match the resonance of the oscillator), and then a sonotrode (to do the same thing I believe). The sonotrode has a particular profile of its own.

What is the purpose of the wedge shape of the sonotrode profile and the slots?

If I replace both with a single flat sheet of metal (as in (b)), tuned to the resonance of the oscillator as will the professional version be - what will I lose in terms of performance from the professional version?enter image description here

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    $\begingroup$ Related question. $\endgroup$
    – AJN
    Commented Dec 8, 2023 at 12:19

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The purpose of the various tapers and bulges along the length of the booster and sonotrode is to 1) extract the greatest amount of energy being fed into it by the oscillator, and then 2) to yield the greatest amount of oscillation amplitude right at the point of contact between the sonotrode and the workpiece.

A piece of sheet metal is too light and too flexible to permit either of these conditions from being met.

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