Ultrasonic welds on recycled shells are catching up

Ran a 6 mm overlap ultrasonic weld on a 30D recycled nylon/elastane shell this week and matched 301 lockstitch seam strength while trimming about 8 g per jacket by skipping tape… Anyone else dialing in sonotrode pattern to avoid gloss on matte PU backers and seeing better durability past 20 wash cycles than TPU film bonds?

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I’ve kept matte PU looking matte by running a chilled anvil around 12°C with the same ‘6 mm overlap’ — held up past 25 washes and outperformed our TPU film bonds. Small caveat: dipping below about 8°C made the elastane go a bit boardy after laundering. Have you tried light fixture cooling instead of changing the sonotrode pattern?

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