Breakthrough in the Volkswagen ID Buzz Carpet Assembly

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.

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‍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) is exactly the right solution in this case. It can be integrated into the injection molded part, which simplifies production, reduces costs and enables complete design freedom.

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‍The Solution: Testing MM-Welding®

‍Adler Pelzer recalled the MultiMaterial-Welding solution they had previously encountered. They were immediately convinced by the solution; however, more tests were needed. First, to test the welding on a wet carpet, since the carpet will be waterjet trimmed prior to MM-Welding process. Secondly, to test with SLS (printed) prototypes in full carpet which will be built in an actual car for the OEM for evaluation. The testing was organized quickly, and the solution proved to be more 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.

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‍Innovative Technology

‍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.

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‍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’s challenges. 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 better visual appearance and aesthetics that it was also decided for the running series production of the 5-seater variant, resulting in the increase of the volume by 40 %.

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‍Customer Benefits

1. 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.
2. 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.
3. Optimized production: With one-sided installation and fewer parts involved, cycle time, overall weight, and costs are significantly reduced.
4. 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 solution has significantly improved the reliability and efficiency of automotive interior parts. This success story with the Volkswagen ID Buzz project highlights the importance of continuous innovation and customer-centric solutions in the automotive industry. Together with Bossard, they developed a new benchmark solution for the carpet assembly in automobiles. The success is a joint effort of the openness and confidence from Adler Pelzer and the technical excellence of MultiMaterial-Welding technology, which justifies the solution.