What's Ultrasonic Radial Wave Used in Sewing Machine?

The cumulative sales of ultrasonic radial wave exceeded 300 sets!!

Since the establishment of the company, our company has been specializing in ultrasonic application research in various directions.

In order to solve the problem that ultrasonic welding has been unable to meet the continuous linear welding, our company invented ultrasonic radial wave. Combined with the design precedent of Dukane, an international outstanding peer (see Figure 1), and combined with the structural characteristics of our transducer, we designed our own ultrasonic radial wave.

After repeated improvement and testing, the radial wave is becoming more and more stable, and the beating rate is controlled within 0.001um.

After several years of continuous feedback from the terminal, we have developed two radial waves, respectively 11.5mm weld and 15mm weld. Combined with some customers can not solve the synchronous feedback, they built a complete sewing system, which can be directly applied to the contact welding system.

Won the market praise. The customer's continuous high requirements, to achieve our continuous quality improvement. As of January 2025, our ultrasonic radial wave system has obtained two patents, selling well in many markets at home and abroad, with cumulative sales exceeding 300 units, becoming the largest ultrasonic radial wave system in circulation and holding on the market.

If you have any material that requires a continuous seam welder and the weld is within 15mm, please contact us to inquire about this product!

An ultrasonic rotary horn sewing machine is a specialized industrial equipment that combines high-frequency ultrasonic vibrations with rotary motion to perform seam sealing, cutting, and sewing of synthetic fabrics and nonwovens without traditional needles or threads.

1. Working Principle

Ultrasonic Vibration:

A rotary horn (sonotrode) spins while vibrating at 20–40 kHz, generating friction heat (150–250°C) to melt synthetic fibers (e.g., polyester, polypropylene).

Pressure from the rotary anvil creates a molecular bond at the seam.

Continuous Process:

Fabric passes between the rotating horn and a pressure roller, enabling high-speed, uninterrupted sealing/sewing (up to 20 meters/minute).

2. Key Components

Component                                                    Function                                                    Material/Specs

Rotary Horn                                           Transmits ultrasonic vibrations              Titanium alloy (TC4)

Anvil Roller                                             Provides counter-pressure                         Carbide-coated steel

Ultrasonic Generator                      Converts electricity to high-frequency AC 1–2 kW output, frequency tracking

Servo Drive System                          Precise speed control                                    ±0.5% speed accuracy

3.Typical Applications

Medical Textiles:

Surgical gowns, masks (e.g., PP melt-blown layer bonding)

Blood filters (seamless tubing connections)

Packaging:

Sterile barrier pouches (ISO 11607 compliant)

Automotive:

Airbag stitching (high-strength nylon seams)

Apparel:

Sportswear (seamless waterproof seams)

The ultrasonic sewing machine core is the core component of ultrasonic technology in textile processing. It transforms the traditional sewing "needle and thread puncture" into "high-frequency vibration fusion", which completely changes the way synthetic fiber materials are connected.