Using a lapped seam, PVC-coated hybrid textiles with uniform thickness were bonded by continuous ultrasonic welding and conventional joining method with the help of hot air tape welding technique for weather protection purposes. Three fundamental sewing parameters at two distinct levels and three primary welding parameters at three levels based on 6 and 12 mm welding widths were used. To consider the effect of welding and sewing parameters on seam strength, full factorial designs of experiments were designed, fabricated, and tested. The thermal behavior and possibility of chemical conversion in the welding zone under the influence of ultrasonic vibrations were examined. Variation in width of heat-affected zone of weld seam was measured. The seam strength of ultrasonic weld seam compared with that of conventional seams, and superior seam strength yielding parametric levels were assessed. The parametric influence of both joining techniques on seam quality and their tendencies in the relationship were analyzed statistically. The weld seam strength (1256.392 and 2116.93 N/50 mm) was optimized numerically and identified its trend with the variation of the weld seam. The discovered relationship led to the conclusion that the variation in the weld seam can be used to estimate the tensile strength of the weld seam through the developed effective numerical model as a non-destructive testing method, and its outcome was successful as a destructive testing method. The result shows that the ultrasonic weld seam provided a higher tensile strength ( > 75%) than the conventional seam for both evaluated welding widths and obtained statistically significant results.