Ultrasonic Welding Sewing Machine

ULTRASONIC
FABRIC
WELDING
MACHINE
Presented by:
Amna Usman 20-NTU-TE-0110
Aqsa Zulfiqar 20-NTU-TE-0113
Faryal Fatima 20-NTU-TE-0115
Fatima Shoukat 20-NTU-TE-0116
Hira Maqsood 20-NTU-TE-0120
TABLE OF
CONTENTS
Ultrasonic Welding
Ultrasonic Welding Machine
Features of Ultrasonic Welding
Machine
Working Principle
Comparison with Lock Stitch
Superimposed Seam
Quality Parameters
Applications
Disadvantages
1 Conclusion
ULTRASONIC
WELDING
Ultrasonic welding is an industrial
technique whereby high-frequency
ultrasonic acoustic vibrations are
locally applied to work pieces being
held together under pressure to create
a solid-state weld.
The development of the ultrasonic
technology started in 1960s for metals
and thermoplastics.
For textiles, the frequency of
ultrasonic is usually between 20kHz
and 40 kHz.
2
WHY ULRASONIC
WELDING?
Ultrasonic assembly uses ultrasonic vibratory energy
which is transmitted through the parts to melt and
bond thermoplastic materials And joining thin sheet
gauge metals and other lightweight materials.
This technique is fast, efficient, non- contaminating
and requires no consumables.
In ultrasonic welding, there are no connective bolts,
nails, or adhesives necessary to bind the materials
together.
3
ULTRASONIC
FABRIC WELDING
MACHINE
Ultrasonic fabric welding
machine provide rapid
sewing, sealing, trimming
and embossing of
synthetic fabrics without
needles, thread or other
consumables.
4
MACHINE
PARTS
5
FEATURES
Ultrasonic sewing machine requires no
waiting time and achieves continuous
operation at high speed.
High productivity and no smoke or
fumes produced.
Easy to operate.
High accuracy.
Pressure regulation.
Speed control.
Operating frequency of 20Khz, low
noise level.
6
Ultrasonic sewing machine can perform
sewing, sealing, trimming and embossing
simultaneously in one quick pass, greatly
improving work efficiency.
Various patterns are available for
hemming, lacing and embossing on
different fabrics, the power is adjustable
according to the material and thickness.
Moulds are easy to change, a variety of
patterns can be changed according to
customer’s preferences.
7
WORKING PRINCIPLE
The ultrasonic vibration is
transmitted from the horn to
the material.
Frictional heat is developed
where they touch.
This momentary heat and
pressure from the roller
fuses the edges of the fabric
and plies join together.
A cutting edge is used on the
anvil to cut and seal the
edges.
8
Working of Ultrasonic Welding Machine
9
Superimposed Seam on
Non-Woven using
Ultrasonic Welding
10
Superimposed Seam on
Non-Woven using Lock
Stitch Machine(Stitch
Class=301)
11
COMPARISON WITH
LOCK STITCHED
SUPERIMPOSED SEAM
Testing Machine
and Samples
Results
Seam Strength
Quality Parameters
12
Testing Machine
and Samples
Machine:
Textile Tensile
Strength Tester
Japan-1992
ASTM D 5035
Sample: 100%
Polypropylene
13
GSM=153
Testing
14
By Grab Method
Before After
15
By Strip Method
Ruptured Samples
16
Results
Seam strength
Ultrasonic Lock Stitched
S.No. Welded Seam Seam
Strength(kg) Strength (kg)
1. 4.3 8.9
2. 3 10
3. 3.5 6
Average Value 3.6(kg) 8.3(kg)

17
Quality Parameters
Appearance
Ultrasonic welded seam is more fine and neat
Time Duration
Ultrasonic Welding machine takes less time
and increase production
Maintenance
Expensive setup
High maintenance cost and energy consumption
18
Applications
Ultrasonic welding is used for:
Joining fabrics edge to edge without seam
allowance,
Joining fabrics by overlapping with seam allowance,
Hemming without seam – fixing the edge,
Hemming with seam,
Hemming with elastic or not elastic band,
Straight superimposed seam with cutting in case of
home furnishing,
Ribbons and trims, and
19 Ballistic vests and body armour.
underwear
outerwear
outdoor clothing
active sportswear
medical products
technical textiles of all
kinds
automotive textiles
non-wovens
20 packaging.
Disadvantages
Cutting and sewing in one process is not possible
with rounded shapes. Common in apparel they
still have to be cut before ultrasonic welding
Work with thermoplastic materials or a high
content of thermoplastic material in the
substrate. If this is not given, an adhesive film or
band is required.
Design by thread thickness or color is not
possible.
Different pattern making regarding the seam
21 might be required.
CONCLUSION
Ultrasonic welded seam shows good

elasticity depending upon the type of
rotating wheel.
Zig-zag pattern allow more elongation than
vertical stripes.
An additional trimming material could turn
22 down the elasticity to zero or very high.

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ULTRASONIC

1. 4.3 8.9

Average Value 3.6(kg) 8.3(kg)

Ultrasonic welded seam shows good

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