The LYCRA Company , a global leader in innovative and sustainable fiber solutions for the personal care industry , will partner with Dukane , a manufacturer specializing in ultrasonic bonding technology for hygiene products and nonwovens, to showcase their latest collaborative ultrasonic bonding technology at INDEX™ 26 in Geneva, Switzerland, May 19-22 .
Since 2014, the two companies have collaborated to advance ultrasonic bonding solutions, helping diaper manufacturers improve product softness, fit, and performance while reducing energy consumption, material waste, and maintenance costs. Ultrasonic bonding technology creates bonding channels between two layers of nonwoven fabric, mechanically securing elastic fibers without the need for adhesives. Dukane’s patented rotary and rigid ultrasonic bonding systems achieve high-speed, adhesive-free assembly by delivering precisely controlled ultrasonic energy to the nonwoven substrate.
Originally developed to prevent snagging and unraveling in stockings, LYCRA FUSION™ fiber can now be integrated with nonwoven layers during ultrasonic bonding. Its core-sleeve structure blends with the surrounding material, enhancing ultrasonic bond strength and providing superior yarn resilience. When used in conjunction with Dukane’s advanced ultrasonic bonding modules, manufacturers can achieve precise positioning of elastic fibers, improve bond integrity, and ensure consistent product performance, while completely eliminating quality fluctuations associated with hot melt adhesives.
Doug Kelliher, Executive Vice President of Product at The LYCRA Company, stated, “As ultrasonic bonding technology becomes increasingly prevalent in the hygiene products industry, our long-standing collaboration with Dukane is expanding our technological capabilities while preparing for commercial-scale production. We are delighted to launch LYCRA FUSION™ fibers designed specifically for the personal care sector, which offer superior performance during ultrasonic bonding, resulting in fewer breakage points and higher bond strength.”
Based on a shared commitment to innovation, The LYCRA Company and Dukane are combining fiber research and development with ultrasonic process engineering to drive the wider application of adhesive-free elastic materials in nonwovens.
Justin Lafferty, Global Product Development Manager for Dukane’s Nonwovens business, stated, “From ultrasonic lamination to precision heat sealing and cutting, our technologies are designed to achieve consistent quality, global scalability, and sustainable production. By combining LYCRA FUSION™ fiber-propelled ultrasonic bonding technology, we not only help our customers improve product performance but also achieve more efficient production.”
Welcome to The LYCRA Company booth ( 2151 ) and Dukane booth ( 1568 ) at INDEX™ 26 to learn more about hygiene products and nonwoven solutions.
About The LYCRA Company
The LYCRA Company innovates and manufactures fiber and technology solutions for the apparel and personal care industries, with leading consumer brands including LYCRA® , LYCRA HyFit® , LYCRA® T400® , COOLMAX® , THERMOLITE® , ELASPAN® , SUPPLEX® , and TACTEL® . Headquartered in Wilmington, Delaware, USA, The LYCRA Company is renowned globally for its sustainable products, technological expertise, and marketing support. The LYCRA Company focuses on adding value to its clients’ products by developing unique and innovative technologies that meet consumer needs for comfort and durable performance. For more information, please visit thelycracompany.com .
About Dukane
Headquartered in St. Charles, DUKANE is a global leader in ultrasonic bonding technologies for the hygiene and personal care industry. Unlike single-solution bonding systems, Dukane offers a range of ultrasonic bonding modules designed to replace adhesive processes in hygiene and personal care manufacturing. Manufacturers can choose the appropriate bonding technology based on product design, production speed, and long-term operational goals. Dukane’s flexible platform supports intermittent and continuous fusion, as well as blade and rotary technologies, preventing manufacturers from being confined to a single technology path. To learn more, please visit dukane.com/nonwoven .
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