Welded seams not only reduce bulk, weight and materials, they improve performance by eliminating the needle hole, a potential area for saturation in hard shells and leakage in soft shells. Welded seams also create a wonderfully clean finish on both the interior and exterior of the garment – increasing the functional elegance of our already streamlined shell designs.

Welded seams offer greater compressibility and better wet-weather performance than sewn seams. Patagonia uses two construction methods for stitch-free seams – one for waterproof shells and one for soft shells.

Welded Composite Seams – Waterproof Shells
Patagonia's advanced stitch-free construction for shells with a waterproof barrier (patent-pending) uses a form of sonic welding, reinforced with thin mesh and backed by flexible tape. This unique construction method minimizes weight, speeds dry time and reduces abrasion that can compromise fabric performance.

Glued Seams – Soft Shells
Patagonia soft shells with stitch-free construction use a lap-gluing technique. Stitch-free seams help speed dry times and reduce bulk to create the best performing soft shells possible.