WEST CHESTER, Pennsylvania, February 29, 2016 – Sonobond Ultrasonics announced today that its SeamMaster® High Profile Ultrasonic Sewing Machines are being used to help assemble children’s underwear used for bedwetting protection.  Several dozen machines have been purchased by companies needing to produce fully-sealed seams that prevent leaks from occurring between the absorbent insert and the rest of the panty.  Sonobond’s machines bond the insert pocket’s water-repellent material to form a leak-resistant barrier that’s strong and comfortable.

“Our rotary sewing machines utilize ultrasonic technology to provide the waterproof seams needed in the panty’s inner pocket,” says Sonobond Vice President Melissa Alleman. “Since both the horn and pattern wheel rotate during the fabric bonding process, the seams are also soft and smooth against the skin.”

“In addition to these bedwetting protection panties, our machines can be used to assemble other types of incontinence panties and personal hygiene products.”

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 100 percent synthetic woven and nonwoven materials or blends containing up to 40 percent natural fibers. 

Resembling a traditional sewing machine, the Sonobond ultrasonic sewing machine channels the ultrasonic vibrations between a rotating horn and wheel, producing a localized heat buildup which causes the synthetic fibers to soften and fuse.  This creates a strong molecular bond that’s impervious to moisture.  Explains Alleman, “the resulting barrier seams are sealed, secure, ultra-reliable and soft-to-the-touch without the leaking issues caused by stitch holes, glue gaps, fraying or unraveling.”

Technology to Speed Production

The SeamMaster® Ultrasonic Sewing Machine seals, seams and trims in one step, making it up to four times faster than conventional sewing machines and 10 times faster than adhesive methods.  Since additional measures required by traditional assembly methods to ensure barrier seams are also eliminated, some manufacturers have been able to boost output by more than 25 percent.

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

Achieving Life-Saving Specifications

Sonobond’s ultrasonic rotary sewing machines also help manufacturers of body armor achieve National Institute of Justice (NIJ) standards that have become increasingly stringent as law enforcement, military personnel, Secret Service and CIA agents, and emergency responders don protective gear to ensure their safety.  In fact, most major ballistic vest manufacturers now use Sonobond machines to satisfy NIJ standards requiring body armor 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 inner nylon shell are perfectly fused,” explains Alleman.  “Once again, the ultrasonic technology utilized by Sonobond’s ultrasonic sewing machines reduces any risk of water or moisture damage to the interior contents, ensuring personal safety.”

Quick Adaptation and Incorporation into Existing Assembly Processes

Since operating the SeamMaster® Ultrasonic Sewing Machine is similar to a conventional sewing machine, workers 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.  Additionally, the machines are available as modular units that can be integrated into production lines and custom equipment. 

Free Ultrasonic Bonding Viability Test

To ensure that our equipment satisfies your requirements, Sonobond offers a free, no-obligation Ultrasonic Bonding Viability Test to produce sample assemblies with your own woven or nonwoven synthetic material or fabric blend.  We also provide service and technical support before, during and after installation, ensuring that our equipment is properly incorporated into your production process.

Leading the Industry

A pioneer in ultrasonic technology, Sonobond holds more than 150 patents, including the first for ultrasonic metal welding, awarded in 1960, when the company was known as Aeroprojects.  In the ensuing 56 years, Sonobond has established and maintained a well-earned reputation for innovative and quality-engineered products.  Today, the company manufactures a complete line of ultrasonic welding and bonding equipment used by leading firms in the electrical, automotive, appliance, HVAC, solar, aerospace, filtration, medical, body armor and apparel industries.

Visit Sonobond at IDEA’16

To view Sonobond equipment and speak to our representatives, see us at IDEA’16, May 2-5, in Boston, MA.  We’ll be in Booth # 1044.

Learn More

For more information on Sonobond’s ultrasonic bonding technology and equipment, or to submit materials for a free Ultrasonic Bonding Viability Test, click here.  For immediate assistance call 800-323-1269, 610-696-4710, or email This email address is being protected from spambots. You need JavaScript enabled to view it..