Buying questions
How are nonwovens laminated, and which method should I choose?
Glue, heat and extrusion each solve a different problem. The wrong one shows up as stiffness, blocked pores or a delamination claim two months later.
At a glance
Specification at a glance
| Method | Bond | Breathability | Typical use |
|---|---|---|---|
| Hot melt glue | Adhesive dots or spray | Kept if pattern is open | Hygiene laminates |
| Thermal calender | Partial melting | Reduced at bond points | Bicomponent webs |
| Extrusion | Molten polymer layer | Blocked unless breathable film | Barrier laminates |
| Ultrasonic | Local melting | Kept outside weld points | Medical seams |
What each method does to the hand
Glue applied in a dot pattern keeps most of the softness and most of the breathability. Thermal calendering flattens the web at the bond points, which increases stiffness. Extrusion adds a continuous layer, which is a barrier decision, not a lamination detail.
Why delamination happens
Three causes: insufficient adhesive add-on, untreated surface, or contamination such as silicone or dust. All three are testable before the roll ships, which is why a peel test belongs in the specification rather than in the complaint file.
Send the question with your specification
Tell us the product, the weight you run now and the market it sells into. We answer with the grade, the test values and the documents you will need.
Questions
Common questions
Can breathable laminates keep their permeability?
Yes, with an open adhesive pattern or a breathable film. Specify the target permeability after lamination, not before.
What peel strength is normal?
It depends on the product. State the value with the test method and the specimen width, then keep it in the specification.
Is ultrasonic lamination expensive?
Tooling costs more than glue, but running cost is often lower and there is no adhesive to declare.