Procedure of Ultrasonic Sewing / Sealing / Lacing / Cutting onto Fabric
Sales@altrasonic.com The most application of ultrasonic onto fabric is ultrasonic sewing (sealing), ultrasonic fabric cutting and ultrasonic lacing, which applying ultrasonic a horn to trqansmit ultrasonic energy onto fabric and a roller as working tooling under pressure to process on fabric to form sewing (sealing), cutting or lacing. This procedure is widely appied in garment industry, such as for underwear, bra, spot wear, etc, and medical industry, such as face mask, surgical cap, surgical gown, etc.
1) Ultrasonic cutting on fabric:
Ultrasonic fabric cutting uses cutting roller to work combining with ultrasonic horn to cut fabric. The cutting roller designed with cutting blade. It can cut one fabric layer, two layers or more, limited by ultrasonic specification’s ability. The cutting can be linear or curve. After ultrasonic cutting, the cutting edge is sealed, so the cutting edge is nor puffed, while the sealed edge also keeps soft, not discomforting skin. Ultrasonic cutting on textile is widely used for the production of underwear and bra. For the application in garment tailoring (used on ultrasonic sewing machine), the cutting roller is designed with a fabric pulling tooth for feed-in cloth. It is necessary to put the specification roller design, including the angle of cutting blade, depth of cutting blade and pulling tooth, and the tolerance between blade and pulling, which is depends on fabric thickness and hardness.
2) Ultrasonic Sewing (Sealing):
Ultrasonic Sewing (also said as ultrasonic sealing) is a kind of fabric process procedure base on ultrasonic welding onto fabric. During ultrasonic sewing, a roller designed with welding tooling rolling to work combing with ultrasonic horn under pressure to weld two or more fabric layers together. The welding pattern is designed according to detail requirement, such as patter specification, welding tooth’s height and distance, which is defined by ultrasonic sewing quality including the sewing strength, sewing out- look and water-proof or air-tightness, etc, as well as fabric specification (fabric thickness and material composition). And the width of sewing will be limited by fabric specification and ultrasonic capacity.
3) Ultrasonic Sewing (Sealing) and Cutting:
Most of time, it request to cut away the extra material after weld two or more fabric layers together. To meet this need, it requests to design both welding tooth and cutting blade onto the roller to work combining together with ultrasonic horn. During operation, the welding and cutting work synchronously. This kind of procedures is widely use onto both textile and nonwoven. Besides the consideration mentioned in item 1) & 2), here it is necessary to mentioned that there is height tolerance and between cutting blade and welding tooth exits defined by fabric thickness. Also, it need to consider the gap between welding tooth and cutting blade, which depends on out-look the mostly but not the only.
4) Ultrasonic lacing:
Ultrasonic lacing is mostly used for the decoration for garment. Normally, because of the width of lacing pattern, the roller is much wider than that for fabric welding or cutting, which also request ultrasonic in much higher power. During ultrasonic lacing, the lacing roller will lace designed pattern onto fabric under pressure together with ultrasonic horn. Because normally it requests to cut off the extra material, the roller pattern requests to be designed as blade-like. The lacing can be used onto single layers, double layers or double layers with filling material between.
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