A joint project of the Navy Clothing and Textile Research Facility and a Rhode Island company could see the military branch’s newest uniforms being fabricated by ultrasonic welding, rather than sewing machine thread — a high-tech development that may actually bolster U.S. manufacturing.
Welded seams, which are forged when two pieces of fabric are basically melted by sound waves, could be the latest trend in Navy wear, The Associated Press reported. The military’s joined with Propel LLC to see if researchers can devise a way to assemble one of the Navy’s most expensive items, the parka — which costs more than $190 for each one — using welded seams and other adhesives.
The technique could save time and money during the manufacturing process. Currently, the parka — as well as other Navy uniform items — uses several different types of stitches that require the transfer of the cloth from sewing machine to sewing machine.
Ultrasonic welding would also make the uniforms lighter and stronger, AP reported.
Propel LLC has been testing the manufacturing process for over a year.
“This was a good way for us to to start to get an understanding of what the current state of the art is,” said Cleveland Heath, the technical program manager at the Navy facility in Natick, Massachusetts, AP reported.
The thread method allows for air holes and water permeation, Propel President Clare King said in the AP report. But welding is airtight.
“We have a lot of opportunity to improve the garments and also effect change at the factory level,” said Ms. King, AP reported. “Some of these technologies have been used in factories overseas, but we have no knowledge base here of how to do them or how to implement them.”
North Face, for example, sells some model jackets with welded seams — but these are made overseas.
One immediate glitch to overcome: Seams that are welded are normally done in straight lines. Welding seams around corners and curves has proven to be very expensive, AP said.
But if the Navy can figure out how to incorporate welded seaming into its clothing, the manufacturing industry on American soil would receive a massive boost, said Augustine Tantillo, president of the National Council of Textile Organizations, in the AP report. Why? The military is required by law to make all its uniforms in the United States.
• Cheryl K. Chumley can be reached at cchumley@washingtontimes.com.
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