Ultrasonic Cutting for Synthetic Fabrics

Ultrasonic Cutting for Synthetic Fabrics

Ultrasound: the secret to cutting-edge textile production

Ultrasound technology has revolutionized the textile sector, offering a series of advantages that improve the quality, efficiency, and versatility of textile production.

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1. Fast and reliable welding: Ultrasound technology allows fabrics to be welded quickly and reliably, eliminating the need for seams or stitches. This reduces production times and improves the aesthetics of the finished product.
2. Elimination of fraying: Using ultrasound for cutting fabrics prevents fraying, ensuring clean and professional edges without requiring additional finishing.
3. Versatility: Ultrasound technology can be used to work with a wide range of fabrics, including synthetic, non-woven, and thermoplastic materials. This allows textile manufacturers to experiment with new materials and expand their production capabilities.
4. Better joint strength: Ultrasound welds create strong and durable joints, ensuring greater fabric strength. This is particularly important in sectors such as clothing, where the durability and strength of seams are crucial.
5. Elimination of needles, threads, and adhesives: Ultrasound technology eliminates the need for needles, threads, or adhesives for fabric processing. This simplifies the production process, reduces costs, and makes the final product more environmentally friendly.
6. Precision and control: Ultrasound offers a high level of precision and control during the cutting and welding process of fabrics. This allows for consistent and high-quality results in every stage of production.
7. Lower energy consumption: Ultrasound technology requires less energy compared to traditional methods such as sewing or using heat for welding. This leads to overall lower energy consumption and reduced costs for the company.
8. Design flexibility: Ultrasound welding allows for creating joints with complex and detailed shapes, opening up new design possibilities in the textile sector. This enables manufacturers to create unique and innovative products.
9. Reduction of harmful emissions: By using ultrasound technology, it’s possible to avoid the emission of toxic fumes during the welding process. This contributes to a safer working environment and reduced environmental impact.
10. Automation and efficient production: Ultrasound technology can be integrated into fully automated machines, allowing for efficient and continuous production. This reduces manual labor and increases production speed.

Benefits of ultrasonic technology in textile sector

The advantages listed above demonstrate how ultrasound technology is revolutionizing the textile sector, offering advanced solutions and improving the efficiency and quality of textile production. In the textile industry, ultrasound technology is installed in various automated systems to perform a wide range of applications. Below, we will describe in detail some of the most common systems:

1. Ultrasound Welding Machines: These systems allow for precise and reliable welding of synthetic fabrics, joining material edges using ultrasound technology. This process eliminates the need for threads or adhesives, creating strong, durable, and seamless joints.
2. Ultrasound Cutting Machines: These systems use ultrasound technology to perform precise cuts on fabrics, ensuring clean and fray-free edges. Ultrasound cutting provides greater precision compared to traditional methods, reducing the risk of material damage and increasing cutting process efficiency.
3. Ultrasound Sewing Machines: These systems enable fabric sewing using ultrasound technology. Ultrasound sewing creates strong and waterproof seams without the use of threads or needles. This sewing method is particularly suitable for synthetic and waterproof fabrics.
4. Ultrasound Zipper Application Machines: These systems allow for the rapid and precise application of zippers onto fabrics using ultrasound technology. Ultrasound zipper application provides greater strength and durability compared to traditional sewing or adhesive methods.
5. Punching: The ultrasonic punching process allows the fabric shearing and, at the same time, a welding of the edges to be obtained. Widely used in the filtration industry and in the medical industry, it also allows the possibility of cutting customized geometries, since the sonotrode and contrast are designed according to the specifications given by our clients.
6. Ultrasound Lamination Machines: These systems laminate fabrics or materials together using ultrasound, creating a protective layer or fusion effect. Ultrasound lamination provides greater wear resistance and enhances the waterproof properties of materials.
7. Ultrasound Trimming Machines: These systems cut or trim excess fabric or material using ultrasound technology. Ultrasound trimming ensures clean and precise edges without the need for further processing or finishing.
8. Ultrasound Marking Machines: These systems use ultrasound to create marks or codes on fabrics, providing clear and permanent identification. Ultrasound marking is a fast and efficient method for applying labels, serial numbers, or other information on fabrics.
9. Ultrasound Cleaning Machines: These systems use ultrasound to gently clean fabrics, removing dirt, stains, or odors without damaging the materials. Ultrasound cleaning is particularly effective for delicate fabrics or those difficult to clean with traditional methods.

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Applications

PUNCHING

CONTINUOUS WELDING

ULTRASONIC WELDING AND CUTTING PROCESS (PORTABLE)

ULTRASONIC CUTTING AND WELDING PROCESS

STEP-BY-STEP ULTRASONIC WELDING

GUILLOTINE ULTRASONIC CUTTING

ULTRASONIC BONDING

ULTRASONIC CUTTING

ULTRASONIC WELDING AND CUTTING ON CIRCULAR LOOMS (RAFFIA BIG BAGS)

Required thermoplastic materials

The synthetic fabrics that work best with ultrasonic cutting machinery are those that contain thermoplastics with similar melting temperatures and compatible molecular structures.

In order for the ultrasonic cutting to work properly, synthetic fabrics should all share the following characteristics:

• Wide melting range
• High friction coefficient
• Uniform thickness
• At least 25 % of thermoplastic contents
• Enough stiffness and thickness to take the energy on the material’s interface (0, mm / 0, mm minimum)

Polyester is considered to be the most suitable synthetic material to be subjected to ultrasonic applications.

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Moreover, ultrasounds can generate strong and long-lasting seams in synthetic elements like Nylon 6 and Nylon 6/6 as well.

Most polyolefins (polypropylene and polyethylene), on the other hand, show excellent welding characteristics, plus they are very lightweight. This makes them to lend themselves to various industrial uses.

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Ultrasonics is created by converting electrical energy in the generator into mechanical vibrations in the converter and ultrasonic stack. This mechanical vibration travels through the ultrasonic stack, through the sonotrode and into the material. The standard frequencies used are between 20 and 35 kHz with an amplitude of 10 to 50 μm. The thermoplastic portion of the material is stimulated, heated up, and melted. The actual weld process is fast: Thanks to the use of rotating tools such as anvil drums, up to 800 m of nonwovens can be processed per minute. The anvil drum has an individual surface structure to focus the ultrasonic energy precisely. This allows for an exact weld through various processes.

A constant distance between the material being processed and the tools is important for optimal results, and this is guaranteed via the precise MICROGAP control technology. It ensures that the distance always remains consistent regardless of the thermal expansion of the tooling during the weld process.

Contact us to discuss your requirements of ultrasonic machine. Our experienced sales team can help you identify the options that best suit your needs.