Installation of an MM-Welding LiteWWeight® zEPP fastener
Success Stories
New Milestone: Advancing Fastening Solutions in the Automotive Industry
Storopack and Bossard have teamed up to create custom crash pads for a luxury car maker, launching the first automated line for LiteWWeight® zEPP fasteners in EPP foam parts, marking an industry milestone.
It all started with a call from the development manager of a German car manufacturer on an ordinary Monday. The task was to produce and deliver custom-made crash pads made of EPP foam for their latest premium-class model. These pads are assembled in the side doors of the car to provide maximum protection for the driver and front passenger in the event of a side impact. But how to solve fastening for the given material?
New Materials Mean New Challenges
"EPP foam has, despite or precisely because of its porosity, unparalleled properties in terms of weight and elastic strength. However, a challenge arises when we need to join parts made of such material. Alternatives such as adhesive bonding or in-molded elements quickly reach their limits in terms of load-bearing, process reliability and strength, especially when it comes to high-requirement applications like the relevant crash structure,” says Ulli Raab, Project Manager at Storopack.
“We had to find a different solution, and we were looking for a partner with the expertise to support us holistically in design, manufacturing and assembly.” This is where Bossard came in. “With our expertise in fastening and engineering, we are capable of providing valuable guidance to our customers in identifying suitable options,” explains Christian Busch, Business Development Manager at Bossard.
“Our approach encompasses various factors such as material type, material architecture, design, manufacturing processes, assembly, and testing, all aimed at ensuring that the fastening solution perfectly matches the application.”
Innovative Technology and Engineering to Meet Requirements
To meet customer requirements, Bossard and Storopack decided to use Bossard’s MM-Welding® technology-platform. This innovative technology involves partially liquefying thermoplastic materials using ultrasonic waves to create a precise, safe, and durable connection. It was precisely for the requirements of connections within EPP that LiteWWeight® zEPP technology was developed. Suitable for various EPP densities, it delivers strong, precise bonding within seconds.
“Our engineering team modified the existing LiteWWeight® zEPP fastener according to the requirements of Storopack and the car manufacturer, enabling the integration of the connection geometry into the design of the desired crash pad.” The flexibility of the process as such, and the design & prototyping capabilities of the engineers, proved that the newly created LiteWWeight® zEPP WSH was the ideal solution to the joining challenge.
Milestone in the Industry
Although delivering large quantities of products to big car manufacturers can be a challenge, Storopack and Bossard embraced it with the same enthusiasm as the project itself. Together, they have developed and established a new automated system concept, including many additional requirements for automobile series parts. This is the first system of its kind in the world, and the partnership between Storopack and Bossard has gone “hand in hand” through the entire process, from prototype to final installation, resulting in a world-first.
High Quality, Optimized Throughput, Zero Waste
The automated production line boasts extremely short cycle times, enabling precise automatic installation of two connecting elements per part, with three parallel applications possible.
The MultiMaterial-Welding® solution has successfully passed all OEM tests, and each part is individually detected by cameras and sensors. “Only when the entire assembly process is perfect does it receive the required RFID label”, says Christian Busch. Quality control is monitored in real-time using big data, artificial intelligence, and software to ensure full process monitoring. “This is ‘Poka-Yoke’ in its purest form, and it is a unique feature in such applications and processes worldwide.”
In conclusion, the collaboration between Storopack and Bossard has resulted in a groundbreaking solution for the automotive industry, combining cutting-edge technology with an innovative approach to problem-solving. The success of the project highlights the importance of collaboration and a multidisciplinary approach in today’s fast-paced, constantly evolving market.
Our collaboration with Bossard has led to the world’s first automated production line for installing LiteWeight® zEPP fasteners into EPP foam-shaped crash pads, setting a milestone in particle-foam fastening in the automotive industry.
Customer Benefits at a Glance
- Precision Fastening: A fastening solution designed to meet the specific requirements (Expert Design) of crash pad assembly ensures optimal performance and safety.
- Cutting-Edge Technology: Innovative MM-Welding® technology enables precise, safe, and durable connections, enhancing the overall strength of the assembly
- Streamlined Production: The automated production line reduces manufacturing time and costs, optimizing throughput without compromising quality.
- Zero Waste Commitment: Meeting the automotive industry’s zero-compromise standards, the solution ensures virtually zero waste, reflecting a commitment to sustainability and efficiency.