Ultrasonic Sewing and Cutting Machine
Ultrasonic seamless sewing technology is a new type of textile processing method that uses high-frequency ultrasonic vibration (usually between 20Kh and 40Khz) to bond materials together through heat and friction, forming a strong seamless connection. Ultrasonic seamless sewing technology eliminates the problem of thread ends in traditional sewing, with stronger joint stitching and higher durability. Mainly used in the clothing manufacturing industry of sportswear and underwear; The automotive and aviation industries use soundproof and waterproof materials; The medical textile industry, including seamless bandages and surgical gowns.
Why Choose Us?
Application Areas
Ultrasound has a wide range of applications across various fields. Different frequencies and power levels are suited for specific uses, and each application benefits from these variations, making ultrasound a versatile tool in many industries.
Sales Market
Our products are sold in many countries, including the United States, Canada, Russia, South Korea, Indonesia, Colombia, Germany, Poland, South Africa, the Netherlands, Hungary, France, Vietnam, Bulgaria, the United Kingdom, Mexico, and the United Arab Emirates and so on. Our main customers are agents experienced in ultrasound technology and end users.
Our Products
FUNSONIC specializes in developing and manufacturing ultrasonic equipment. Our product line includes ultrasonic spray coating machines, ultrasonic nozzle spray shaping machines, ultrasonic welding equipment, ultrasonic cutting equipment, and ultrasonic liquid processing equipment. We also offer a variety of ultrasonic core components.
Our Team
Hangzhou FUNSONIC Ultrasonic Company was founded in 2018, led by multiple experts with over 10 years of practical experience in the field of high-power ultrasonic. The team members are mainly born in the 1980s and 1990s, all of whom have a college degree or above. Has strong competitiveness and challenge, used for innovation, responsibility, and accountability.
What is Ultrasonic Sewing Machine?
Ultrasonic sewing machine uses high frequency vibration to bond two or more layers of materials together. Vibration can quickly accumulate heat energy between materials, cause materials to melt, and make materials firmly stick together.
Advantages of Ultrasonic Sewing Machine
Increased Efficiency and Productivity
A ultrasonic sewing machine can greatly increase the efficiency and productivity of your business. Traditional sewing machines require time-consuming processes such as threading needles, changing bobbins, and adjusting tension. With an ultrasonic lace machine, there are no needles or thread involved, making the process much faster and more efficient. The high-frequency vibrations bond the fabrics together instantly, allowing for quicker production times and higher productivity levels.
Cost Savings
Ultrasonic sewing machines can also help save costs in the long run. Traditional sewing machines require needles, thread, and bobbins, which can add up over time. Additionally, these machines can often experience issues such as thread breakage or needle jams, which can lead to additional costs for repairs and maintenance. it eliminates the need for these supplies and the associated costs, making them a more cost-effective option in the long run.
Enhanced Product Quality
Using ultrasonic sewing machine can greatly enhance the quality of your products. The high-frequency vibrations create a strong and durable bond between fabrics, resulting in a more secure hold that can withstand wear and tear. Additionally, this type of bonding does not create puncture holes in the fabric, as traditional sewing methods do. This means that the final product will have a cleaner, more professional appearance, which can help attract more customers to your business.
Versatility
It can be used to bond a wide range of fabrics, including synthetic materials, plastics, and even metals. This versatility allows businesses to create a variety of products and expand their offerings. Additionally, ultrasonic bonding can be used to create intricate designs and patterns, adding a unique and personalized touch to your products.
Eco-Friendly Option
Using ultrasonic sewing machine can also be a more eco-friendly option for your business. Traditional sewing methods require the use of needles and thread, which can create waste and contribute to environmental pollution. Ultrasonic bonding, on the other hand, does not create any waste and does not contribute to pollution. This can help your business reduce its environmental impact and appeal to eco-conscious customers.
Clothing industry: Ultrasonic sewing machines can be used for linear stitching, curve stitching, splicing stitching, etc. of clothing, improving production efficiency and product quality.
Shoes and hats industry: Ultrasonic sewing machines can be used for sewing and decorating shoes and hats, improving production efficiency and product quality.
Luggage industry: Ultrasonic sewing machines can be used for sewing and decorating luggage, improving production efficiency and product quality.
Home industry: Ultrasonic sewing machines can be used for sewing and decorating household items, improving production efficiency and product quality.
Medical industry: Ultrasonic sewing machines can be used for sewing and decorating medical supplies, such as surgical gowns, medical bed sheets, etc.
Components of Ultrasonic Sewing Machine
Ultrasonic Generator
The ultrasonic generator is the power source that generates high-frequency electrical energy. It converts electrical energy from the mains power supply into high-frequency electrical signals suitable for driving the transducer.
Transducer
The transducer is a key component that converts the high-frequency electrical energy from the generator into mechanical vibrations. It typically consists of piezoelectric elements that expand and contract rapidly in response to the electrical signal, generating high-frequency mechanical vibrations.
Horn or Sonotrode
The horn, also known as the sonotrode, is a metallic component that amplifies and focuses the mechanical vibrations generated by the transducer. It is designed to transmit the vibrations to the fabric layers, creating localized heat and pressure for bonding or cutting.
Anvil
The anvil is a flat surface or support against which the fabric layers are pressed during the ultrasonic sewing process. It provides stability and helps in achieving uniform and consistent bonding.
Fabric Handling Mechanism
Ultrasonic sewing machines usually include a fabric handling mechanism that holds and moves the fabric layers through the machine. This mechanism may consist of rollers, belts, or clamps to ensure proper alignment and tension of the fabric during the sewing process.
Control Panel
The control panel is the interface that allows the operator to set and adjust various parameters of the sewing machine. It may include controls for power output, frequency, speed, and other settings depending on the machine's features.
Safety Features
Ultrasonic sewing machines often include safety features to protect operators and prevent accidents. These features may include emergency stop buttons, safety sensors, and protective covers to shield the operator from the ultrasonic vibrations and hot components.
Cooling System
Since ultrasonic sewing machines generate heat during the bonding process, they often incorporate a cooling system to prevent overheating. This may involve air cooling or water cooling mechanisms to maintain optimal operating temperatures.
Electrical and Control Wiring
The machine contains electrical wiring and control cables that connect the various components and transmit signals between them. These wiring systems ensure proper communication and coordination among the components.
Frame and Housing
The frame and housing provide the structure and support for the components of the sewing machine. They help in maintaining stability and protection for the internal components.
What is the difference between ultrasonic sewing and traditional sewing machines? Ultrasonic woven fabric sewing uses high-frequency oscillation to transmit the sound wave from the welding head to the welding surface of the working material, which immediately causes the working material molecules to produce friction and reach the plastic melting point, thus completing the rapid dissolution of solid materials and welding.
Compared with traditional sewing machines, it has the following advantages:
★The use of ultrasonic welding can eliminate the need for needle and thread, save the trouble of changing needle and thread frequently, and eliminate the situation of broken thread joint of traditional suture. It can also conduct clean local shearing and sealing for textiles. At the same time, stitching also plays a decorative role. It has strong adhesive force, can achieve waterproof effect, clear embossing, more three-dimensional relief effect on the surface, fast working speed, good product effect, and more high-grade and beautiful; The quality is guaranteed.
★Using ultrasonic wave and special steel wheel processing, the sealing edge will not crack, damage the cloth edge, and have no burr and curl.
★No preheating is required during manufacturing and continuous operation is possible.
★It is easy to operate. It is not much different from the traditional sewing machine operation method. Ordinary sewing workers can operate it.
★Low cost, 5 to 6 times faster than traditional machines, and high efficiency.
The Functions of Ultrasonic Sewing Machines
High speed stitching
Ultrasonic sewing machines have the function of high-speed stitching, which can complete a large amount of stitching work in a short time and improve production efficiency.
Multiple sewing methods
Ultrasonic sewing machines can complete various sewing methods, such as linear sewing, curve sewing, splicing sewing, etc., which can meet the production needs of different products.
Automatic adjustment
The ultrasonic sewing machine can automatically adjust the sewing parameters and positions according to different product requirements, achieving precise sewing.
High precision sewing
Ultrasonic sewing machines use high-precision ultrasonic generators and vibrators to achieve high-precision sewing and improve product quality.
Energy conservation and environmental protection
The ultrasonic sewing machine adopts an efficient ultrasonic vibration system, which can greatly reduce energy consumption and noise pollution, achieving energy conservation and environmental protection.
Key Features of Ultrasonic Sewing Machine
Ultrasonic Transducer
At the core of the machine is an ultrasonic transducer that converts electrical energy into high-frequency mechanical vibrations (typically in the range of 20,000 to 40,000 Hertz).
Horn (Sonotrode)
The ultrasonic transducer is connected to a horn or sonotrode, a metal tool designed to amplify and transmit the ultrasonic vibrations to the fabric layers.
Fabric Layers
The layers of synthetic fabric or nonwoven material to be joined are placed between the horn and a fixed anvil or a rotating wheel, depending on the machine's design.
Pressure and Ultrasonic Energy
When the machine is activated, the horn applies pressure to the fabric layers, compressing them together. Simultaneously, the ultrasonic transducer generates high-frequency vibrations in the horn. These vibrations travel through the horn and into the fabric layers, creating localized heat due to friction at the contact points.
Melting and Bonding
As a result of the localized heat generated by the ultrasonic vibrations, the synthetic fibers in the fabric layers melt and fuse together at the contact points. This creates a strong and permanent bond between the fabric layers.
Seam Formation
By controlling the movement of the horn and the fabric layers, the ultrasonic sewing machine can create various seam patterns, including straight lines, curves, and decorative designs. Some machines are equipped with computer-controlled systems for precise seam formation.
Cooling and Solidification
After the ultrasonic energy is turned off, the melted fibers cool and solidify rapidly, forming a durable and flexible bond. This bond is typically as strong as the surrounding fabric and can withstand washing, wear, and stress.
There are two main reasons why the flower wheels of ultrasonic sewing machines are prone to wear and tear.
Firstly, high hardness flower wheel molds have direct contact with ultrasonic amplitude changing rods during relative motion, making them prone to wear. The mold used for ultrasonic sewing machine needs to meet a certain standard for surface hardness due to its need for cutting, punching, and other operations. However, if the surface hardness of the mold is too high, it will wear the surface of the amplitude lever, which is uneconomical; If the surface hardness of the mold is low, the mold is prone to damage and affects production efficiency. Therefore, the surface hardness of the mold needs to be controlled slightly lower than the hardness of the ultrasonic amplitude lever, which to some extent increases the possibility of mold wear.
Secondly, improper operation or untimely maintenance of the ultrasonic sewing machine during use may also lead to wear of the flower wheels. For example, if the equipment runs too fast, there is no paper tape or film padding, insufficient pressure, the flower wheel or steel mold has worn out, and the power voltage is too low, all factors may cause flower wheel wear.
Device setup issue
It may be due to the device being set too fast in the initial setup or subsequent adjustments. This may be due to operator error or intentional acceleration of speed in order to speed up work.
Control system malfunction
The control system of the ultrasonic sewing machine is responsible for controlling the speed of the flower wheel. If there is a malfunction in the control system, it may cause an abnormal increase in the speed of the flower wheel.
Motor issue
The motor is a key component that drives the rotation of the flower wheel. If the motor malfunctions or is damaged, it may affect the speed of the flower wheel, resulting in excessive speed.
Transmission system issue
The transmission system is responsible for transmitting the power of the motor to the flower wheel. If there is a malfunction in the transmission system, such as damage or looseness of components such as chains and sprockets, it may also cause abnormal flower wheel speed.
Why Does the Ultrasonic Sewing Machine Produce Wrinkles When Welding Double-Layer Fabric?
Problems
Poor quality of raw materials: If the double-layer fabric used is of poor quality and one side lacks elasticity, wrinkles are prone to occur.
The distance between the ultrasonic sensor and the pressure roller is not appropriate: The distance between the ultrasonic sensor and the pressure roller is a crucial step when welding double-layer fabrics, and if the distance is not appropriate, wrinkles can also occur.
Excessive welding speed: Excessive welding speed is also one of the reasons for wrinkles, because when the welding speed is too fast, ultrasonic energy cannot be evenly transmitted to the entire fabric.
Solution
Choose high-quality raw materials: In order to avoid wrinkles caused by insufficient elasticity of the fabric, it is best to choose high-quality and elastic double-layer fabric.
Adjustment of the distance between the ultrasonic sensor and the pressure roller: When adjusting the distance between the ultrasonic sensor and the pressure roller, it is necessary to accurately grasp. If the distance is appropriate, the welding will not only be wrinkle free, but also have a more beautiful lace effect.
Control welding speed: Reasonably control the welding speed to fully transmit ultrasonic energy, thereby avoiding wrinkles and other unattractive effects.
What Is the Cause of the Non Woven Fabric Welded with an Ultrasonic Sewing Machine That Is Easily Torn and Not Firmly Welded?
Unqualified raw materials
Firstly, it is necessary to check whether the non-woven fabric materials used comply with relevant national standards, such as fiber quality, density, thickness, and other indicators that meet the requirements. If the quality of non-woven fabric is poor, it will lead to unstable welding.
Inappropriate ultrasonic frequency
The working frequency of the ultrasonic sewing machine determines the size of welding energy. If the frequency is too low, the welding quality is poor and the welding points cannot be fully bonded. If the frequency is too high, the welding point is prone to burning. Therefore, it is necessary to adjust the ultrasonic frequency based on the non-woven fabric material used.
Insufficient welding time
If the welding time is insufficient, the melting of the welding points is not sufficient, resulting in unstable welding and easy tearing. Therefore, when welding, it is necessary to extend the welding time appropriately to ensure that sufficient melting state is reached.
Welding temperature too high
If the welding temperature is too high, the non-woven fabric is prone to melting and deformation, resulting in unstable welding points. Therefore, when welding, it is necessary to reduce the welding temperature appropriately to ensure that the solder joints achieve sufficient adhesion.
Maintenance of Ultrasonic Sewing Machine
Daily maintenance
Also known as routine maintenance, the main content is to clean, lubricate, fasten parts that are easy to loosen, and check the integrity of parts. Most of this type of maintenance is external to the equipment.
Primary maintenance
The main content is the general tightening, cleaning, lubrication, fastening, and some need to be adjusted. Daily maintenance and first-level maintenance can be completed by the frontline operator.
Secondary maintenance
The main content is internal cleaning, lubrication, partial disassembly inspection and adjustment.
Three-level maintenance
It is mainly to check and adjust the main part of the equipment, and replace the parts that meet the specified wear limit when necessary. In addition, the wear and tear of the main components is measured, identified and recorded. Secondary maintenance and tertiary maintenance are required for the operator to complete the training.
Our Certifications
Our Factory
FUNSONIC was established In 2018. It is composed of several engineers with more than 20 years of practical experience in the field of high-power ultrasound. FUNSONIC focus on the development and manufacture of ultrasonic equipment, such as ultrasonic spray coating machine,ultrasonic nozzle spray shaping machine, ultrasonic welding equipment, ultrasonic cutting equipment, ultrasonic liquid processing equipment, various kinds of ultrasonic core components. Also we will provide customized services according to the needs of our customers.
FAQ
As one of the most professional ultrasonic sewing and cutting machine manufacturers and suppliers in China, we're featured by quality products and low price. Please rest assured to buy ultrasonic sewing and cutting machine for sale here from our factory. Also, customized service is available.
Ultrasonic Metal Treatment,