Process and apparatus for making a pre-fastened diaper

A process for forming an article, said process comprising:

• a providing of a first panel layer having a first inboard portion and a first outboard portion;
• a positioning of a second panel layer onto said first panel layer, said second panel layer having a second inboard portion and a second outboard portion;
• an attaching of said inboard portion of said first panel layer to said inboard portion of said second panel layer;
• an attaching of a side region of a tab web to the inboard portion of at least one said first and second panel layers to provide a first assembly web;
• a providing of a fastening mechanism attached to an appointed securement surface of said tab web;
• a folding of the outboard portion of at least one of said first and second panel layers, thereby providing a folded layer and a protruding layer;
• a severing of said first assembly web to provide a plurality of individual panel assemblies;
• a configuring of each panel assembly to include a tab web portion, a folded layer portion and a protruding layer portion;
• a providing of an article segment having a first waistband portion, a second waistband portion and an intermediate portion that interconnects said first and second waistband portions;
• an attaching of the protruding layer portion of at least one panel assembly to a side section of said first waistband portion of said article segment;
• a transverse folding of said article segment along a transversely extending fold line to provide a folded article segment;
• and
• an attaching of said folded layer portion of the at least one panel assembly to a side section of said second waistband portion of the folded article segment.