This study proposes a novel method to mechanically characterize the performance of individual bonds in low‐density, thermomechanically bonded nonwoven fabrics. Commercial bicomponent, polyethylene/polypropylene (PE/PP), nonwoven fabric was laser cut into bowtie‐shaped specimens for uniaxial tensile testing so that the central region of each specimen contained an individual bond. Three groups, each composed of 20 specimens, were tested with their longitudinal axes oriented along the machine direction (MD), the cross direction (CD), and at 45° between these two directions (DD). Prior to testing, the intrinsic variation in areal density and fiber orientation in the region surrounding the individual bond were quantified via orientation and relative basis weight parameters. During testing, images of the specimens were acquired to determine the occurrence of fiber breakage, bond deformation, and bond cohesive failure. Maximum force, stiffness, and orientation parameters were found to be significantly different among the three specimen groups (p < 0.01) but the relative basis weight was not (p > 0.01). The stiffness and maximum load were linearly correlated with both the areal density and fiber orientation. Pre‐existing voids or windows within the bond lowered the maximum force for specimens with the longitudinal axes aligned with the MD. These voids had no influence on the maximum force achieved by the specimens aligned with the CD and DD. The bonds in these specimens were observed to deform less than the bonds in the specimens with the longitudinal axes aligned with the MD. The results indicate the importance of the fiber structure surrounding the bond on the tensile properties, deformation and failure mode of individual bonds within the nonwoven fabric. POLYM. ENG. SCI., 59:311–322, 2019. © 2018 Society of Plastics Engineers

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