A respiratory apparatus may employ ultrasonic welds (410). The ultrasonic welding may be used to join a variety of headgear, mask and accessory components. This process may enhance comfort, fit and/or performance of the joined components and/or overall mask assembly. A component may be a single layer component such as a textile or fabric, or a composite or multiple layer component such as fabric and foam composites, or outer fabric layers (402-1) and inner spacer fabrics (402-3). Further, a component may be a strap, some other headgear component, a mask component, an accessory component or the like.