WILMINGTON, DEL. -- The LYCRA Company, a global leader in innovative and sustainable fiber solutions for the personal care industry, and Dukane, a manufacturer of ultrasonic bonding technologies for the hygiene and nonwovens market, are showcasing their latest co-developed advances in ultrasonic bonding at INDEX™ 26, taking place in Geneva, Switzerland, from May 19-22.

Join The LYCRA Company and Dukane at INDEX™ 26 in Geneva, as they showcase their latest advances in ultrasonic bonding for nonwovens, including new LYCRA FUSION™ fiber for personal care that delivers superior snapback.
Join The LYCRA Company and Dukane at INDEX™ 26 in Geneva, as they showcase their latest advances in ultrasonic bonding for nonwovens, including new LYCRA FUSION™ fiber for personal care that delivers superior snapback.
Since 2014, both companies have collaborated to advance ultrasonic bonding solutions that help diaper manufacturers improve product softness, fit, and performance while reducing energy consumption, material waste, and maintenance costs. Ultrasonic bonding creates bonded channels between two layers of nonwoven materials, mechanically securing elastic fibers without using adhesives. Dukane’s patented rotary and rigid ultrasonic bonding systems enable high-speed, adhesive-free assembly by delivering precisely controlled ultrasonic energy into nonwoven substrates.

LYCRA FUSION™ fiber, originally developed to prevent snags in hosiery from turning into runs, can now fuse to nonwoven layers during ultrasonic bonding. Its sheath/core construction fuses with surrounding materials, strengthens ultrasonic bonds, and delivers superior yarn creep (snapback). When this fiber is paired with Dukane’s advanced ultrasonic bonding modules, manufacturers can achieve precise elastic placement, improved bond integrity, and consistent product performance while eliminating the variability associated with hot-melt adhesives.

“As ultrasonic bonding gains traction in the hygiene industry, our longstanding collaboration with Dukane focuses on expanding technical capabilities while preparing for commercial scale-up,” said Doug Kelliher, executive vice president, product, The LYCRA Company. “We’re excited to introduce LYCRA FUSION™ fiber for personal care, which provides excellent performance with fewer breaking points and improved bond integrity during the ultrasonic bonding process.”

Building on this shared commitment to innovation, The LYCRA Company and Dukane are aligning fiber development with ultrasonic process engineering to support broader adoption of adhesive‑free elastic attachment in nonwovens.

“From ultrasonic lamination to precision sealing and cutting, our technologies are engineered for consistent quality, global scalability, and sustainable production,” said Justin Lafferty, global product development manager - nonwovens, Dukane. “By advancing ultrasonic bonding with LYCRA FUSION™ fiber, we’re helping customers improve product performance while enabling more efficient production.”

Explore more hygiene and nonwovens solutions at The LYCRA Company stand (2151) and the Dukane stand (1568) at INDEX™ 26.