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Today when the newest high‐tech fibers and sophisticated material constructions are used for the production of sails, forming 3D sail shape from 2D sailcloth has still remained very primitive because classic sewing techniques are mostly used. Since, the clothing and technical textile industry has been recently using some of contemporary joining techniques (ultrasonic, thermal, high‐frequency) replacing classic sewing, this paper seeks to investigate the possibility of ultrasonic welding in the production of sails, and the strength of obtained bonds.

Concerning the aim, sails were made employing the classic and modern (ultrasonic) joining technique whereby bonding parameters such as amplitude and welding speed, geometry of anvil wheels were varied. Objective quality evaluation of the bond made in such a way, was performed in order to be more exact about its strength.

Based on the obtained results it has been concluded that ultrasonic welding may successfully replace the classic sewing of sails, selecting an anvil wheel with suitable engraving and optimal parameters of welding (speed and amplitude).

Selection of optimal welding parameters not only increases the sail's bond strength in comparison with classic seam, but also provides sail air impermeability, being one of the basic aerodynamic requirements for sail making.

This paper has presented the novel and successful approach in 3D sail shape forming from 2D sailcloth.

Examines the thirteenth published year of the ITCRR. Runs the whole gamut of textile innovation, research and testing, some of which investigates hitherto untouched aspects. Subjects discussed include cotton fabric processing, asbestos substitutes, textile adjuncts to cardiovascular surgery, wet textile processes, hand evaluation, nanotechnology, thermoplastic composites, robotic ironing, protective clothing (agricultural and industrial), ecological aspects of fibre properties – to name but a few! There would appear to be no limit to the future potential for textile applications.

Examines the fourteenth published year of the ITCRR. Runs the whole gamut of textile innovation, research and testing, some of which investigates hitherto untouched aspects. Subjects discussed include cotton fabric processing, asbestos substitutes, textile adjuncts to cardiovascular surgery, wet textile processes, hand evaluation, nanotechnology, thermoplastic composites, robotic ironing, protective clothing (agricultural and industrial), ecological aspects of fibre properties – to name but a few! There would appear to be no limit to the future potential for textile applications.