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. Since 2014, the two 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,” says 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.”

In other news, The Lycra Company launched Adaptiv fiber, a breakthrough stretch fiber, already trusted by leading global apparel brands, for use in baby diapers, disposable hygiene products, adult incontinence, and feminine care. Lycra Adaptiv fiber is engineered to address key unmet needs in hygiene and personal care. According to the company’s proprietary research, these include fit flexibility, shape retention, comfort in motion, ease of use, and stay-in-place performance. Its unique polymer formulation adapts to the wearer’s body, delivering a soft, easy stretch that enhances comfort; a secure fit to help minimize leakage; inclusive sizing for a wider fit window; easy donning and doffing for users and caregivers; and reduced concentrated compression to help minimize red marks on skin.

“Lycra Adaptiv fiber is a major leap forward for hygiene and personal care. This technology adapts to real bodies and how they move—an essential demand of today’s consumers,” says Doug Kelliher, executive vice president, product, The Lycra Company. “By introducing our proven apparel innovation to this space, we help manufacturers deliver a more personalized, comfortable, and secure wearing experience—without adding product complexity.”