Ultrasonic sewing machines

Threadless thermoplastic stitching technology

La ultrasonic sewing machine is an advanced industrial device that enables the continuous welding and without fabric thread synthetics and thermoplastics by means of high-frequency vibrations. In contrast to traditional stitching, which requires the use of needle, thread and mechanical stitching, the ultrasonic stitching machine uses sound energy to fuse materials together cleanly, firmly and without residue.

This technology is becoming established in many industrial sectors where precise, hygienic and durable bonding of flexible plastics or technical and synthetic fabrics is required. The models of the MCR developed by Sonomax Srl represent one of the most advanced solutions currently available on the Italian and European market.

Operation of the ultrasonic sewing machine

Underlying the machine's operation is a piezoelectric transducerwhich transforms electrical energy into high-frequency mechanical vibrations. These vibrations are transmitted through a sonotrode to the surface of the materials to be welded. The pressure exerted between the sonotrode and the contrast wheel generates localised heat that softens materials, allowing molecular fusion and subsequent welding.

The system is completed by:

• Electro-pneumatic drive for pressure control
• Electronic speed control
• Digital user interface with real-time display of power, energy, frequency and graphs

The operator can act on various parameters, such as thewidth (adjustable between 30% and 100%) and the sewing speedto obtain a seam perfectly adapted to the specific application.

Advantages over traditional methods

• No needle and thread: reduces production costs and time, avoiding fabric breaks, perforations, jams and replacements
• Clean and hygienic finishideal for medical, filtering and PPE products
• Continuous and uniform unionConsistent and repeatable stitching even on large batches
• High production speedthanks to the soft start system and programmable cycles
• Minimal thermal impact: does not damage heat-sensitive materials
• Customisation of contrast wheelsfor patterns, edging or microperforations

Industrial fields of application

• Filter industryWelding of pleated filters with high precision
• Technical textiles and PPE: masks, protective suits, disposable clothing
• Medical and biomedical: welding of sterile materials without contamination
• Automotive: car interiors, cabin filters, technical coatings
• Flexible packaging: aesthetic seals on bags and packages

La modularity of the machine allows integration in automatic installations, operator desks customised or production lines automated with PLC.

Technical requirements and configurations

• Operating frequencies20 / 30 / 35 / 40 kHz
• Power rating400 W to 1500 W
• Brushless motors: separate control of sonotrode and wheel
• Advanced digital technologyReal-time adjustment and monitoring
• Remote interfaceCompatibility with PLCs and industrial systems
• Replaceable castorswithout tools, in seconds
• Optionaldrag pullers, fabric guides, storable programmes

All configurations can be customised to suit production requirements.

All Sonomax models are made in Italy, covered by 2-year warranty and subjected to rigorous functional testing before delivery.

The Sonomax offer for the Italian and European markets

Sonomax Srl is a European benchmark in the ultrasonic welding of thermoplastic materials. The MCR series models are part of a complete range of:

• Manual and automatic welding machines
• Actuators for industrial plants
• High-performance sonotrodes, boosters and transducers

Thanks to in-house know-how, Sonomax offers customised design, specialised technical assistance and fast delivery times.

Frequently asked questions (FAQ)