Sonobond, the leader in ultrasonic technology, presents its SeamMaster ultrasonic sewing machine, designed to meet the manufacturers’ increasing demand for life-saving protective apparel and disposable medical items.

The company that develops ultrasonic rotary sewing machines believes the need to assemble protective apparel quickly and reliably has never been more urgent, as it witnessed at the Expo Produccion trade fair that took place in Mexico City last month and at the Shooting, Hunting, Outdoor Trade (SHOT) Show, in Las Vegas.

“For manufacturers challenged with producing the hundreds of personal protective equipment (PPE) suits required daily by healthcare workers in clinics and countries where the Ebola virus persists, or for those tasked with assembling ballistic vests and PPE equipment to safeguard military, police and other personnel, the capabilities of our equipment are absolutely essential,” commented Melissa Alleman, Sonobond Vice President.

Creating an ultrasonic bond

Sonobond’s SeamMaster ultrasonic sewing machine was originally developed in 1991 to meet tough OSHA regulatory requirements for barrier seams in medical garments and disposable items.  Instead of needles, thread, glues or other adhesives, Sonobond’s equipment uses a patented rotary system, coupled with high-frequency vibrations, to bond synthetic or blended materials containing up to 40 percent natural fibres.

Resembling a traditional sewing machine, the SeamMaster ultrasonic sewing machine channels the ultrasonic vibrations between a horn and rotating wheel, producing a localized heat build-up, which causes the synthetic fibres to soften and fuse. This creates a strong molecular bond that’s impervious to moisture. 

Technology to speed production

Since it bonds and trims in one step, the SeamMaster ultrasonic sewing machine is up to four times faster than conventional sewing machines and 10 times faster than adhesive methods.  Additional measures required by traditional assembly methods to ensure barrier seams are thereby eliminated, enabling some manufacturers to boost output by more than 25%, the company reports.

In addition to PPE suits, this sealing capability makes Sonobond’s ultrasonic sewing machines ideal for assembling medical protective apparel that meets AAMI standards for fluid protection.  This includes surgical gowns, facemasks, caps and booties, as well as disposable healthcare products, such as mattress covers, lint-free wound dressings and medical wipes.

Achieving life-saving specifications

Sonobond’s ultrasonic rotary sewing machines are also said to help manufacturers of body armour achieve National Institute of Justice (NIJ) standards.

More than 35 ballistic vest manufacturers now use Sonobond machines to satisfy NIJ wet-conditioning standards requiring body armour to be waterproof, even after submersion for 30 minutes.

“Bulletproof materials contained in ballistic vests lose their life-saving effectiveness when exposed to water, so it’s imperative that the seams in the outer nylon shell are perfectly fused,” explained Ms Alleman.

Quick adaptation

Since SeamMaster Ultrasonic Sewing Machines are similar to conventional sewing machines, operators require only minimal training. 

The High Profile model is currently the most popular in the series because of its large pattern wheel, high clearance, and ability to accommodate bulky materials and hand-guided operations with tight tolerances and curves, the company reports.  Additionally, the machines are available as modular units that can be integrated into production lines and custom equipment. 

www.sonbondultrasonics.com