Can Ultrasonic Cutter Used for Fabric Cutting?

Introduction

Ultrasonic fabric cutting/cutter(ultrasonic slitting machine/ultrasonic sealing machine) is a technology that uses high-frequency mechanical vibration energy to accurately cut textiles. It is especially suitable for modern textile materials such as synthetic fibers, non-woven fabrics, and composite materials. The following is a detailed analysis of the technology:

1. Principle

High-frequency vibration cutting: The cutter vibrates at a frequency of 20kHz-40kHz (amplitude of about 10-30μm), and melts the fiber through microscopic friction heat (local temperature can reach 200-300℃), achieving burr-free cutting.

Non-contact pressure: Only a slight contact pressure (usually 0.1-5N) is required to avoid deformation of the fabric or displacement between layers.

2. Technical advantages

Features    

Edge sealing                        -Automatically fuse cutting edges to prevent de-threading (no need to lock edges)

Accuracy                               -±0.1mm (suitable for cutting complex curves)

Multi-layer cutting           -Cut more than 50 layers at a time (non-woven masks)

No thermal damage       -Heat-affected zone <0.5mm (laser about 2-3mm)

No dust No fiber debris (applicable to medical clean rooms)

3. Typical application scenarios

Clothing manufacturing:

-Quick cutting of chemical fiber fabrics (polyester, nylon)

-Non-stretching cutting of elastic fabrics (Lycra)

Industrial textiles:

-Automotive interiors (seat fabrics, ceilings)

-Filter materials (meltblown cloth, PTFE membrane)

Medical protection:

-Seamless cutting of disposable protective clothing

-Synchronous welding of medical mask ear straps

4. Key equipment configuration

Blade design:       Titanium alloy blade (lightweight + wear-resistant)    Special coating (such as diamond-like carbon DLC to extend life)

Motion system:      Servo drive + linear motor (speed up to 2m/s)

Visual positioning (automatic pattern alignment)

Cooling system:         Air-cooled/fan-cooled transducer (continuous operation to prevent overheating)

5. Process parameter optimization

python             # Example parameter setting (multi-layer synthetic fiber fabric)

Frequency = 28kHz/35khz    # The higher the frequency, the finer the cutting

Amplitude = 25μm   # Increasing the amplitude can increase the cutting speed

Feed_rate = 0.8m/s     # Feed speed is inversely proportional to material thickness

Pressure = 1.2N    # Excessive pressure will cause deformation of the lower layer of material

Selection suggestions

Thin material high-speed cutting: select 35kHz high-frequency system

Thick composite materials: select 20kHz high-power + rotary horn design

Ultrasonic fabric cutting/cutter technology is reshaping the textile manufacturing industry, especially in emerging fields such as medical protection and smart wearables. Its integrated "cutting + edge sealing" feature can shorten the process by more than 30%, and is one of the key technologies for industrial upgrading.