A Revolutionary Solution for Carpet Assembly in the Automotive Industry
This success story delves into how our customer Adler Pelzer revolutionized the connection of functional parts in the carpet for the Volkswagen ID Buzz by commissioning the MultiMaterial-Welding solution.
The Journey to Innovation
After years of collaboration with Bossard and familiarity with the MultiMaterial-Welding technology, Adler Pelzer reached a pivotal moment in early 2023. A phone call from Adler Pelzer stated: “We have a project where we need MultiMaterial-Welding.”
Adler Pelzer was commissioned to produce carpets for the Volkswagen ID Buzz. Ventilation holes were mandatory, and the initial approach involved directly cutting holes in the carpet, which left room for technical and aesthetic improvements.
Addressing the Initial Challenge
The project’s objective was to find a reliable solution for securing the ventilation grid in the carpet, which posed unique challenges due to its soft and flexible nature. The initial approach used a two-piece clipping solution for the ventilation grid. However, this method proved inadequate because the carpet’s softness allowed it to bend in any direction, causing the clips to fail. This inadequacy highlighted the need for a more advanced and dependable solution.
LiteWWeight® Lotus functionally integrated parts (FIP) are the ideal solution in this case. They can be integrated into the injection molded part, which simplifies production, reduces costs and enables complete design freedom.
Testing the Solution: MM-Welding®
Adler Pelzer remembered MultiMaterial-Welding and was immediately convinced by it; however, more tests were needed. First, to test welding on wet material, since the carpet will be waterjet trimmed prior to the ultrasonic welding process. Secondly, to test with SLS (printed) prototypes in full carpet, which will be built in an actual car for evaluation.
Testing was organized quickly, and the solution proved to be sophisticated and reliable. The integration of LiteWWeight® Lotus geometry with the plastic ventilation grid allowed the part to be welded by an ultrasonic machine within seconds from one side only in the carpet.
How the Innovative Technology Works
The innovative technology involves the partial liquefication of Lotus’ teeth into the fibrous material, creating an unbeatably strong connection with the textile structure.
This solution not only shortened the cycle time drastically due to one-sided installation and fewer parts involved, but it also allowed for design and form freedom, improving overall aesthetics. Additionally, there was a 50 % reduction in parts needed, leading to cost and weight savings.
Successful Prototyping and Production
Thanks to the versatility of the product and the engineers’ skill in design and prototyping, the LiteWWeight® Lotus solution proved ideal for this project.
Initially, the application was intended for the production of 6 and 7-seater variants only. However, after the first prototypes, the OEM was convinced by the superior aesthetics. Therefore, they decided to use the technology also for the running series production of the 5-seater variant, resulting in an increase in volume by 40 %.
We were impressed by the problem-solving mindset of the team, creating value by taking full advantage of the product's outstanding performance. Not only did it solve our technical issues, but it also added aesthetic value and boosted overall efficiency.
Customer Benefits
Revolutionary solution: This advanced approach tackled the challenge of securing ventilation grids in soft, flexible carpet material, providing a reliable and efficient alternative to previous methods and allowing design and form freedom.
State-of-the-art technology: This cutting-edge method involved the partial liquefaction of Lotus’ teeth into the fibrous material within seconds, drastically reducing cycle time and improving reliability.
Optimized production: With one-sided installation and fewer parts involved, cycle time, overall weight, and costs are significantly reduced.
Elevated aesthetics: The nature of the functionally integrated parts and the possibility of one-sided installation significantly enhance the overall aesthetics.
A New Benchmark
Adler Pelzer’s innovative approach with MultiMaterial-Welding's solution has significantly improved the reliability and efficiency of automotive interior parts. This success story with the Volkswagen ID Buzz highlights the importance of continuous innovation and customer-centric solutions in the automotive industry.
Together with Bossard, they developed a new benchmark solution for carpet assembly in automobiles. This success is a joint effort made possible by Adler Pelzer's openness and confidence, as well as the excellence of MultiMaterial-Welding technology.
