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Application And Advantages Of Ultrasonic Seamless Suture Technology

Ultrasonic seam stitching is an advanced technology for joining synthetic materials and blends to create continuous and impermeable seams. Fabrics can be 100% thermoplastic synthetic fibers or blends with natural fiber content up to 40%. Ultrasonic seamless stitching technology is generally achieved by ultrasonic sewing machines. The ultrasonic sewing machine uses a disc-shaped welding head for seam welding, which skillfully converts the longitudinal vibration of the transducer, and the disc-shaped welding head radiates radial vibration 360° outward in the diameter direction, so as to achieve seamless stitching of materials.

During ultrasonic seam stitching, material is fed between a vibrating ultrasonic horn and a stationary anvil (or wheel). High frequency mechanical vibrations (20-40kHz) passing through thermoplastic parts create frictional heat at the interface to gain enough temperature to melt and bond the material. Because the heat required for bonding is generated at the interface (and not from outside the material), the ultrasonic welding process begins right at the interface. For non-synthetic fabrics or blends with more than 40% natural fiber content, place the heat-activated material between two fabrics. The vibration and pressure of the ultrasonic waves melt and penetrate the heat-activated material into the interfiber spaces of the fabric.

Application:

Ultrasonic seamless stitching is playing an increasingly important role in a variety of industries, as well as in garment manufacturing and development.

Apparel Industry

Ultrasonic sewing machines are very fast, clean and economical for garment manufacturers. Ultrasound can be used on a variety of man-made fabrics and plastics, and natural fabrics can also be used with a minimum content of at least 60% thermoplastic. Ultrasonic seamless stitching technology provides beautiful smooth seams for lightweight underwear and sportswear fabrics, and is also ideal for attaching with Velcro and polyester straps. The fabric seams sit completely flat against the body with adhesive tape that is 4 times stronger than sewn seams.

Medical industry

Ultrasonic sewing machines are capable of producing commonly used garments including protective clothing, disposable hospital gowns, shoe covers, face masks, baby warm clothes, filters, bags, curtains, sails and mesh stitching and more. Ultrasonic seams are beneficial in the manufacture of these items because the sealed edges and seams without seam holes will not penetrate chemicals, liquids, blood-borne pathogens or other particles.

Outdoor products industry

Because ultrasonic stitching is air-tight, creating strong seams and reducing the formation of holes, the technology is also used to make outdoor items such as sails and parachutes. The technology is widely used in skiing, cycling, sailing, mountaineering, paddle sports, hiking and other sports clothing, waterproof backpacks, outdoor tents, military equipment and so on.

Advantages of Ultrasound Seamless Suture Technology:

lighter weight

Seamless stitching is lighter in weight than conventional stitching. When dry, they can reduce total seam weight by up to 30%.

strong and stretchable

Seamless bonding is 40% less restrictive than sewn seams and offers excellent stretch and recovery. That means more freedom of movement, more comfort and fewer distractions. The seamless bond is as strong as the stitches and the fabric is softer.

waterproof and airtight

Ultrasonic stitching enhances the garment's water resistance. Because it is adhesive, there are no pinholes for water to penetrate. At the same time, the stitching technology also improves the wind resistance of the material due to the lack of pinholes.

cost savings

Ultrasonic seamless stitching can be used on fabrics containing a large amount of thermoplastic fibers. This technique is less wasteful because it does not require needles, threads, solvents, adhesives or mechanical fasteners. There is no limit to the sewing speed, and there is no need to worry about re-threading the bobbin or changing the spool.

Scope of application

For fabrics and textiles to be used for ultrasonic welding, certain requirements must be met. The material being stitched requires a wide melting range and a high coefficient of friction, while the fabric must always have a consistent thickness. To reach a melting point that allows ultrasonic bonding, the textile must have a minimum thermoplastic content of 20 percent and must have sufficient strength within the material to withstand the welding process.

Ultrasonic sewing is generally suitable for synthetic fabrics because of their thermoplastic properties, which soften and bond when exposed to ultrasonic energy. Polyester and nylon are popular and popular choices of fabric materials for ultrasonic welding and sewing. Nylon is a good fiber choice because of its excellent properties. It is a strong primary fiber; it is elastic when stretched and has excellent abrasion resistance. Polyester (PET) is the most commonly used synthetic fiber overall. Polyester has properties similar to nylon. It has strength and abrasion resistance, and has a permanent heat set.