Thermally Bonded & Calendered Polyester Wadding (Polyfill)

Thermally Bonded & Calendered Low Melt Polyester Wool (Polyfill) 

It is a specialised non-woven material manufactured using a combination of regular polyester (PET) staple fibers and low-melt polyester (LMF) bonding fibers.

During the thermal bonding process, the low-melt component softens and melts at a comparatively lower temperature than the regular polyester fibers. It forms bonding points between the fibers, creating a stable and integrated non-woven structure without requiring conventional chemical adhesives. After thermal bonding, the material undergoes a controlled calendering process in which it passes through heated rollers. This process helps regulate thickness, improve surface uniformity and achieve a relatively compact and consistent structure.

The combination of thermal bonding and calendering provides good structural integrity, dimensional stability and mechanical strength. Depending on the proportion of low-melt fibers, GSM, thickness, density and processing conditions, the material can be manufactured with different levels of softness, firmness, porosity and compression characteristics.

Its fibrous structure can provide air permeability, sound absorption and cushioning properties, depending on the product grade and construction. It can be supplied in roll form and converted into customised widths, thicknesses and shapes for different industrial and technical applications.

Key Features

• Manufactured using regular PET and low-melt polyester fibers

• Thermally bonded fiber-to-fiber structure

• Low-melt fibers provide bonding without conventional chemical adhesives

• Additional calendering for controlled thickness and uniform surface finish

• Good dimensional stability and structural integrity

• Consistent density and compact construction

• Customisable GSM, thickness and fiber composition

• Available in different softness and firmness levels

• Suitable for slitting, cutting and further fabrication