The LYCRA Company and Dukane expand ultrasonic bonding for hygiene products at INDEX™ 26
The LYCRA Company and Dukane are presenting their latest joint developments in ultrasonic bonding technology at INDEX 26, taking place in Geneva from May 19–22.
The two companies have been working together since 2014 to develop ultrasonic bonding solutions for hygiene products such as diapers. Their focus has been on improving softness, fit, and product consistency while also reducing energy use, material waste, and maintenance requirements during production.
Ultrasonic bonding works by creating bonded channels between layers of nonwoven materials without using adhesives. Instead of hot-melt glue, controlled ultrasonic energy mechanically secures elastic fibers inside the structure. Dukane’s rotary and rigid ultrasonic bonding systems are designed to support high-speed production with precise energy control.
A key part of the latest development is the use of LYCRA FUSION fiber in nonwoven hygiene products. The fiber was first developed for hosiery applications to stop snags from turning into runs. In ultrasonic bonding processes, its sheath/core construction allows the fiber to fuse directly with surrounding nonwoven materials.
According to the companies, this improves bond integrity and provides stronger yarn snapback during use. When combined with Dukane’s ultrasonic bonding modules, manufacturers can achieve more accurate elastic placement and more consistent product performance while avoiding some of the variability linked to adhesive-based processes.
Doug Kelliher, executive vice president of product at The LYCRA Company, said the collaboration is focused on expanding the technical capabilities of ultrasonic bonding while preparing for larger-scale commercial use.
He added that LYCRA FUSION™ fiber offers strong performance with fewer breaking points and improved bond quality during ultrasonic processing.
The companies are also aligning fiber development with ultrasonic process engineering to support wider adoption of adhesive-free elastic attachment in nonwoven applications.
Justin Lafferty, global product development manager for nonwovens at Dukane, said the company’s ultrasonic technologies are designed to support consistent production quality and scalable manufacturing. He noted that combining ultrasonic bonding with LYCRA FUSION™ fiber can help producers improve product performance while making manufacturing more efficient.
Visitors at INDEX™ 26 can explore these developments at The LYCRA Company stand 2151 and Dukane stand 1568 during the exhibition in Geneva.
