Sewing thread is traditionally used to join cut components together using a sewing machine, thus providing seams with adequate strength, elasticity, and aesthetic properties. However, traditional thread-seaming produces discontinuous joints and perforated seam structures. Nowadays, sew-free technologies such as ultrasonic welding, adhesive bonding, and laser seaming that involve the melting and cooling of thermoplastics at the joint interface are becoming more or more popular in the apparel industry. Sew-free technologies were first applied to waterproof garments, a product category particularly averse to needles and threads that pierce through fabrics, which creates openings that allow water to seep in. More recently, sew-free seaming has also been found to:
• reduce garment weight, because the seam allowance in traditional thread seaming is reduced
• offer a sleek appearance
• have excellent seam elasticity and resilience
• enhance the overall comfort
Therefore, sew-free technologies have been widely adopted in the manufacture of sportswear and intimate apparel.
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