Surface protrusion formations and methods of manufacturing

A method for assembling elastic laminates and mechanically forming one or more surface protrusions integrally from a garment material, the one or more surface protrusions extending outwardly from a first surface of the garment material, the method comprising:

• (i) wrapping the first surface of a first substrate of the garment material onto an outer circumferential surface of a forming die, the forming die having a first surface, the first surface having a plurality of openings which have a configuration and orientation corresponding with the configuration and orientation of the one or more surface protrusions of the garment material;
• (ii) positioning an elastic film in contact with a second surface of the first substrate on the forming die;
• (iii) advancing a second substrate to position a first surface of the second substrate in contact with the elastic film and the second surface of the first substrate on the forming die;
• (iv) ultrasonically bonding by a source of energy the first substrate together with the second substrate with the elastic film positioned between the first substrate and the second substrate;
• (v) softening the first surface of the first substrate by the source of energy;
• (vi) positioning at least some of the softened first surface into at least one opening of the plurality of openings from the first surface of the forming die;
• and
• (vii) separating the forming die from the garment material to form the one or more surface protrusions integrally from the first surface of the first substrate of the garment material.