Sonobond's Ultrasonic Bonding Technology Increasingly Essential for Ensuring Reliable Body Armor Assembly

More than 30 Leading Manufacturers Use Sonobond Equipment to Achieve Improved Production Speed, Product Durability, Cost-Effectiveness and Compliance with Tough NIJ Standards

WEST CHESTER, Pennsylvania — With armed services personnel, emergency responders, law enforcement officers, and others exposed to more and more perilous circumstances, reliable body armor is absolutely essential for their personal safety. That's just one of the reasons why more than 30 leading manufacturers use Sonobond's ultrasonic technology to assemble their ballistic vests.

"Instead of needles, thread or glue, our equipment uses ultrasonic energy to create strong molecular bonds, resulting in durable, perfectly sealed seams without stitch holes, glue gaps, fraying or unraveling," explains Sonobond Vice President Melissa Alleman. "Sealed seams mean better protection for the bullet proof materials contained in the vest – such as Spectra-Shield® and Kevlar® – ensuring that they are less likely to lose their life-saving effectiveness by being exposed to moisture. They also achieve compliance with National Institute of Justice (NIJ) wet-conditioning standards (NIJ-0101.06) requiring body armor to be waterproof, even after submersion for 30 minutes."

The ultrasonic energy – directed into woven or nonwoven synthetic materials or blends with up to 40 percent natural fibers – results in a rapid heat buildup that causes the synthetic fibers to soften and fuse, creating the strong molecular bond.

Ultrasonic Equipment for Body Armor Assembly

Sonobond's SeamMaster® High Profile Ultrasonic Sewing Machine is perfect for sealing the outer nylon shell of body armor. Its rotary system seals and trims in one quick step, making assembly up to four times faster than with conventional sewing machines and 10 times faster than adhesive methods. In fact, some manufacturers have increased production output by as much as 25 percent since switching from sewing and adhesives machines to ultrasonic bonding technology. The SeamMaster® High Profile Ultrasonic Sewing Machine operates like a traditional sewing machine so only minimal training is required. It is also available as a modular unit for integration into production lines.

Attaching Straps to the Outer Shell of Ballistic Vests

A second machine that's useful for body armor assembly is Sonobond's Ultrasonic PlungeBonder™. It's ideal for attaching coated synthetic straps within the seam of a ballistic vest's outer shell without compromising its integrity, again ensuring the vest's ability to satisfy NIJ submersion standards. The machine can easily attach straps at a rate of five vests per minute.

Free Ultrasonic Bonding Viability Test

Sonobond offers a free, no-obligation ultrasonic bonding viability test, using materials supplied by potential customers, to ensure that its ultrasonic equipment meets the requirements of specific applications. Also, Sonobond provides technical expertise and quality service, assisting customers with questions, customization needs, installation, and on-going technical support.

More than a Half-Century of Industry Leadership

Sonobond is a worldwide leader in the application of ultrasonic bonding and welding technology, holding more than 150 patents, including the first for ultrasonic metal welding in 1960, when the company was known as Aeroprojects. Over the ensuing years, Sonobond has established and maintained a wellearned reputation for innovative and quality-engineered products. Today, the company manufactures a complete line of ultrasonic welding and bonding equipment used by leading firms in the electrical, automotive, appliance, HVAC, solar, aerospace, filtration, medical, body armor and apparel industries.

For more information on Sonobond's ultrasonic bonding technology and equipment for body armor assembly, or to submit materials for a free Ultrasonic Bonding Viability Test, please visit For immediate assistance call 800-323-1269, 610-696-4710, or email Vice President Melissa Alleman at

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