The Benefits of Ultrasonic Welding
Published 14th November 2024
Ultrasonic welding is just one of the services that Redwood can offer to give you the edge when it comes to sealing edges. Alongside our hugely experienced team of traditional seamstresses, ultrasonic welding can provide a cleaner, more clinical way of joining fabrics, which is ideal to meet the stringent standards demanded by medical environments.
But what exactly is ultrasonic welding, how does it work and what are the benefits of using this technique?
What is ultrasonic welding?
Ultrasonic welding is a way of joining technical textiles using the vibration of high frequency sounds, usually in the 20KHz to 40KHz range. This is just beyond the reach of human hearing, which ranges from 20Hz to 20KHz at best (though in reality, most adults can’t hear sounds above 15KHz to 17KHz) – hence the name ultrasonic.
The vibrations caused by these high frequency soundwaves produce low amplitude mechanical vibrations within the fibres of the fabric, which in turn is converted into localised heat energy. This causes the fibres to bond under physical pressure, without the need for any additional adhesives.
According to Science Direct, the exact mechanisms behind ultrasonic welding are still not fully understood, but it is thought to be a mechanical, rather than a chemical process. Fibres within the fabrics bond at a molecular level, with no new chemicals formed as part of the process.
What are the benefits of using ultrasonic welding?
Ultrasonic welding is fast, flexible, clean and low-impact, creating a cost-effective, energy-efficient and high-performance process and delivering a strong, impermeable bond that resists fluids, dust, germs and other contaminants. It even makes bonded fabrics easier to recycle.
Let’s look a little closer at each of these benefits in detail:
- Fast – ultrasonic bonds form almost instantaneously, with no need to wait for adhesives to cure and harden
- Flexible – ultrasonic welding is suitable for long seams, such as medical mattress covers
- Clean – with no messy glues or adhesives, the seal is clean and smart with no risk of drips or run off
- Low-impact – ultrasonic welding does not use direct heat, so there is no thermal damage to the fabrics
- Cost-effective – with no need for adhesives or solvents, needles or threads, ultrasonic welding is relatively low cost compared to other bonding techniques
- Energy-efficient – ultrasonic welding does not require an external heat source making it a highly energy efficient, low carbon technology
- High-performance – unlike adhesive-based processes, where adhesive levels can vary along the length of the seam, ultrasonic welding is precise and consistent throughout
- Strong, impermeable bond – with no stitch holes or low adhesive areas, ultrasonic welding creates a strong seal that is impervious to both air and fluid bourn contaminants
- Easier to recycle – because an ultrasonic welded fabric contains only the original fabric fibres, with no additional sealants or threads, it is easier to recycle
Redwood - the ultrasonic welding experts
As a leading manufacturer of medical mattresses, as well as a wide range of other medical products such as wheelchair cushions, manual handling hoists, incontinence and pressure relief products, Redwood have vast experience in all kinds of production techniques, including ultrasonic welding. You can call on these techniques to support your infection control protocols, protecting both patients and staff, while also making patients feel comfortable and cared for.
Our expert technical team will be happy to share their extensive experience of ultrasonic welding techniques to help you design exactly the products you want us to create. Alternatively, we can offer a full design service based on your requirements, taking your ideas from concept to completion, ensuring the highest standards at every stage.
To hear more about ultrasonic welding, and how it can benefit your technical textiles and medical products, contact Redwood today.
