the Automotive Industry

Automated screwing, driving and torquing are all ways that precision fastening systems streamline the installation of threaded fasteners into automotive components. These systems also directly measure, document and error-check torque and depth values as fasteners are installed, significantly reducing post-assembly quality checks and rework.

Thermoplastic components are often too soft or brittle to be directly threaded into, but by inserting separate metallic threaded nuts into the plastic base material, these components can accept threaded fasteners for a higher-strength, longer-lasting connection.

Industrial adhesives offer another great option for automotive component manufacturing. From light-duty ethylenes up to heavy-duty epoxies, adhesives serve a multitude of applications where low weight, cost and wear are expected.

Many light-duty automotive components rely on friction fits to hold them together, which is where press assembly machines come into play. Interlocking plastic components as well as interference-fit metal components are most commonly pressed during assembly.

Similar to riveting sheet metal, heat staking assembles multiple loose pieces together by compressing a plastic boss down over these materials, forming a retaining cap that keeps all parts permanently attached to each other.

Some critical automotive assembly components must be completely sealed to keep contaminants, moisture or even air from making their way inside. Hermetic sealing fills the components' interior with an inert media (often potting epoxy) so there is no remaining space for contaminants to reach. This fabrication technique is most often used on electrical and electronic components so that no moisture can ingress and lead to a short.

Clip fastening is a very useful solution for light-duty, removable components such as wiring harnesses, framed headliners and trim panels. Automated systems can easily position, align, insert and test attachment clips onto these components, which also eliminates the need for loose fasteners such as screws and pins.

Using high-frequency mechanical vibrations, ultrasonic welding bonds two separate thermoplastic material pieces together by fusing their molecular structures into one. Ultrasonic welding is very common around electronics and sensitive parts, where a fast, high-strength, low-temperature weld can be laid without negatively impacting surrounding features.

No matter which of the above assembly methods may be used to bond loose parts together, many of these parts come with the expectation that they will have a limited or near-zero amount of leakage across their joints. Automated leak testing is another manufacturing solution that can be used to automatically test these leakage rates on products, assuring that leakage specifications are met.