VibroCut is a technology-focused company specialising in hybrid machining solutions based on both ultrasonic and low-frequency oscillation tool holder systems. Founded in 2023 as a spin-off from Fraunhofer IWU, the company combines long-standing development expertise with extensive experience in industrial implementation. Their systems are designed for use on new and existing machine tools, enabling manufacturers to enhance process capability without major machine-side modifications.
A brief description of the company and its activities.
Our work focus on improving precision, process stability and manufacturing efficiency. By integrating hybrid machining into established cutting processes, we support customers in reducing tool wear, improving chip control and achieving higher productivity in demanding materials and components.
Our portfolio comprises complete solutions for hybrid machining, including both ultrasonic and oscillation-based tool holder systems as well as the associated integration and support services. We assist customers throughout the entire implementation process: from evaluating the technological suitability to integrating the systems into existing machine environments and stabilising the process for production use. This is complemented by targeted training and application support, ensuring that the technology can be transferred reliably into industrial practice. Through cooperation with manufacturing companies from various sectors, we have established hybrid machining as a practical approach for improving efficiency and capability in demanding machining tasks.
What are the main areas of activity of the company?
VibroCut’s activities focus on the development and industrial application of hybrid machining technologies.
The core areas include:
- Hybrid machining systems and product development.
VibroCut develops and provides ultrasonic and oscillation-based tool holder systems, ranging from standard solutions to application-specific configurations for both new and existing machine tools.
- Integration and industrial implementation.
The company supports customers in assessing technical requirements, integrating the systems into their machines and establishing stable machining processes under production conditions.
- Training and application support.
Structured training programmes and ongoing application assistance ensure that technologists and operators can use the hybrid machining technology efficiently and reliably.
- Technology development and lifecycle services.
In collaboration with industrial partners, VibroCut develops application-specific process solutions and provides long-term service and maintenance to maintain consistent process capability.
What’s the news about new products/services?
In 2025 VibroCut expanded the application scope of its ultrasonic technology. The VibroCut ultrasonic tool holder system is now available for grinding processes, where it enables more controlled grinding conditions and improved tool performance, and for friction stir welding, where the ultrasonic assistance stabilises material flow and enhances overall process robustness.
These extensions build on the existing system architecture and allow customers to apply ultrasonic assistance in additional manufacturing steps without major modifications to their machines.
What are the ranges of products/services?
VibroCut provides hybrid machining systems that enhance conventional cutting processes by superimposing an additional movement. This movement can be realised as a low-frequency oscillation or as ultrasound, depending on the process and material. The oscillation-assisted approach, implemented with VibroCut oscillate tool holders, enables controlled chip breaking and improves process stability, particularly in turning. The ultrasonic-assisted approach, realised with VibroCut ultrasonic systems, overlays a high-frequency excitation onto the process, which can reduce cutting forces, stabilise material flow and increase robustness in applications such as drilling, deep drilling, grinding and friction stir welding.
Both technology paths are delivered as modular systems that can be integrated into new or existing machine tools. VibroCut supports customers with evaluation, mechanical and control-side implementation, commissioning and process stabilisation. Application engineering assists in analysing process conditions and developing or optimising hybrid machining strategies.
Structured training and lifecycle services ensure stable operation and long-term process reliability.
What is the state of the market where you are currently active?
Hybrid machining technologies such as oscillation- and ultrasound-assisted processes are gaining increasing attention in industrial manufacturing. In sectors with high demands on process reliability and component quality, interest in these solutions has grown, supported by their potential to improve productivity and stabilise machining.
Adoption remains application-driven, often starting with pilot projects before moving into wider production. This reflects both the maturity of the technology and the need for process-specific validation.
Overall, hybrid machining is increasingly viewed as a practical way to extend process capabilities and meet rising quality and efficiency demands.
What can you tell us about market trends?
Manufacturing companies increasingly require machining processes that deliver consistent and predictable results, particularly as automation levels rise and materials become more demanding. Hybrid machining technologies address these needs by reducing process variability and extending the capabilities of conventional cutting methods.
At the same time, the use of difficult-to-machine materials continues to grow, which places additional strain on tools and processes. Oscillation- and ultrasound-assisted solutions provide mechanisms to stabilise these processes and decrease mechanical loads.
Retrofit-compatible systems further support adoption, as they allow manufacturers to enhance existing machine fleets without major investments, aligning well with current efficiency and sustainability objectives.
What are the most innovative products/services marketed?
The key innovation in VibroCut’s offering lies in the industrial realisation of hybrid machining, where an additional movement is superimposed onto a conventional cutting process. VibroCut oscillate introduces a low-frequency oscillation that promotes controlled chip breakage and improves process stability, while VibroCut ultrasonic applies a high-frequency excitation to reduce cutting forces and stabilize material flow.
Both systems translate these physical mechanisms into modular, retrofit-compatible tool holder solutions that can be integrated into new or existing machines. This combination of robust mechanics and practical industrial integration distinguishes the technology from earlier laboratory-based concepts.
Complementary application engineering and process optimization support further enhance the industrial usability of the systems, enabling customers to transfer hybrid machining concepts into production with a high degree of reliability.
What estimations do you have for the end of 2025?
By the end of 2025, hybrid machining is expected to continue its rapid increase as more companies move from pilot projects to regular production use. Ultrasound-assisted processes in drilling, grinding and friction stir welding, as well as oscillation-assisted turning, will remain important application drivers.
Retrofit-capable solutions will play a central role, as they allow manufacturers to improve process robustness without replacing existing equipment. As successful implementations become more visible, similar companies in comparable industrial environments are likely to follow.
Overall, the market is expected to grow steadily rather than abruptly, with hybrid machining increasingly recognised as a mature method for extending process capabilities and improving production reliability.
