Why go ultrasonic?
WHAT ARE THE BENEFITS OF AN ULTRASONIC CUT TOWEL?
The old way to manufacture microfiber towels is to roll the edges around piping material and surge along the sides to create a binding. Having a towel finished with ultrasonic cut presents a certain number of advantages.
Control of the size: Traditional cutting is done by hand with power tools that look like giant saw blades cutting across many layers of material. The result is as precise as the hand of the operator driving the cutting equipment. By contrast, the ultrasonic cutting machine, once calibrated, creates very consistent and reproducible results. The machine can precisely cut a 16 X 16 inches towel. The variability is around +/-0.5% instead of about +/- 3%.
Control of the geometry: Traditional cutting does not guarantee square corners. The ultrasonic cutter will produce towels that are always perfectly square and won't have a parallelogram shape.
Straight edges: When sewn on surging machines, the hand of the operator is guiding the feed of the towel, adding the piping material and the sewing yarn. This results invariably in imperfections of the finished towel. The ultrasonic cutter knows only how to cut a straight line.
No differential shrinking: Microfiber towels can be washed hundreds of times. The towel will maintain its cleaning efficacy, but differential shrinkage between the binding and the yarn in the towel will create wrinkles on the edges, sometimes corners that lifts and can't stay flat. This is totally eliminated with ultrasonic finishing as there is no surging yarn with different characteristics than the towel material itself.
No risk of scratching: Traditional surging results in an extension of the edge with a pigtail that requires cutting with a hot wire. Once the fibers of polyester and polyamide are heated and cool down, they become hard. The corner of the towel is then left with a potentially scratchy edge which if not handled properly or used on a soft surface could scratch.
Absence of label: The true professional detailler or enthusiast does not like having a label sewn on a towel. These are often getting in the way of precision work. Most enthusiasts and professionals of detailing remove the labels before they use a microfiber towel. As there is no surging on ultrasonic cut towels, there is no label attached, and no need to remove it.