CASE STUDIES
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A plastic add-on part on the roof edge spoiler was to be bonded with five individual adhesive tapes – precisely, quickly and reliably. However, the previous solution with individual parts and liner bridges was complex, error-prone and unstable.

INNO TAPE developed a customised adhesive tape assembly in which all five moulded adhesive tape parts lie on a common liner – with positioning aids, grip tabs and optimised packaging. The result: 70% time savings and a stable, reproducible assembly process.

Find out in our case study how well thought-out packaging simplifies complex bonding processes.

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High temperatures, vibrations and tight tolerances: the display bonding process placed the highest demands on materials and workmanship. The first choice of material failed due to vibration damping – the second due to price.

INNO TAPE accompanied the development from the outset, optimised the material, liner and grip tabs, and developed a tailor-made application concept. The result: stable processes, reduced variety and lower costs.

Find out in our case study how material testing and presentation ensure series production capability.

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A glass cover had to be bonded precisely and permanently to a printed circuit board – tightly, partially opaque and reliably. However, the liner adhered too strongly, the moulded parts slipped and the positioning pins stuck to the adhesive. 
 
INNO TAPE developed a solution with a split removable liner, inner liner protrusions for clean placement and additional positioning aids for precise assembly. The result: error-free, stable series processes and a clean appearance.

Find out in our case study how small changes can bring big process advantages

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A premium manufacturer was planning the bonding of an illuminated radiator grille – a component with high requirements in terms of appearance, impermeability and process reliability.

The acrylic foam adhesive tape that was initially used was convincing in terms of adhesive strength, but in this case it had reached its limits. INNO TAPE finally worked with the material manufacturer to develop an alternative based on PE foam.  The result: uniform sealing and stable processes.

Find out in our case study how an adapted choice of material and optimised packaging stabilised series production.

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A premium car manufacturer developed a new lighting system – known as a light carpet – which illuminates the entrance area of a vehicle. The first fastening solution met the basic requirements, but was above the target price and offered potential for optimisation in terms of process reliability and wetting.

The early involvement of INNO TAPE enabled the material, contour and design to be further developed in a targeted manner. Close coordination with the customer and the material manufacturer resulted in both technical improvements and an efficient series solution.

The result: significant cost reduction, OEM-compliant adhesive performance and a stable assembly process – achieved through partnership and cooperation.

Find out how development partnerships create economic efficiency in our case study.

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A sensor strip that opens the boot with a foot movement should be glued instead of clipped in future. However, the material released solvents, one substrate had to be primed, the other did not.

INNO TAPE combined two adhesive tapes with different properties and also took care of the entire application process – from priming to repackaging. The result: ready-to-install, tested parts and stable processes in just nine months.

Find out in our case study how individual material combinations solve complex requirements.

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A component on a printed circuit board was being disrupted by external radiation – safe series production approval was at risk.

Standard products did not offer a solution: shielding alone would have caused short circuits, while insulation alone would not have reduced the interference.

Thanks to our manufacturer-independent material selection, we developed a three-layer structure that combines shielding, insulation and fixation – ready for installation, reproducible and UL-compliant.

The entire case study provides insight into the structure, material selection and benefits for series production.

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A roof spoiler moulded part in the premium segment had to deliver high holding forces, withstand extreme temperatures and fit inconspicuously into the installation space – without additional process steps.

Standard solutions failed because conventional gripping tabs either interfered with assembly or failed at an unfavourable angle during final removal. A moulded part was therefore developed with a pre-folded, process-neutral fixed and fabric-reinforced tab that is only activated in the decisive OEM step. In addition, the roller geometry was optimised so that more rollers could be used in parallel, reducing material waste.

The result: secure final fastening, stable removal function, faster assembly and fewer changes in the process – ready for series production and robust for high quantities.

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When bonding battery modules in a premium electric vehicle, it became apparent that the intended material solution, while functional, would have been unnecessarily expensive and difficult to handle.

The standard procedure – individual parts without design modifications and additional grip tabs – would have meant more process steps, a higher risk of errors and longer cycle times. Instead, a technically equivalent, significantly cheaper material alternative was chosen and the packaging was redesigned: integrated liner protrusions replace separate tabs and serve as clear grip points, including a defined removal sequence and colour coding.

This allowed the tape to be processed safely, quickly and with few errors – at up to 60 moulded parts per vehicle. The result: 60% savings in material costs, simplified handling, less assembly effort and a stable series production process.

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A battery base required a defined spacer layer to allow air to circulate in the high-voltage area — achieved using double-sided adhesive tape with exactly the right thickness.

The standard procedure would have resulted in high material and tooling costs and unnecessarily burdened the cycle time for over 9.6 million parts. Instead, materials were compared and sampled, and an economical alternative was chosen that is around 20% cheaper. At the same time, the geometry was specifically adapted to the existing application device: double application, clear grip zone across the full width and simplified punching design without radii.

This allowed the spacer to be put into series production quickly, reliably and with stable handling. The result: lower costs, better cycle times and a robust solution for millions of units.

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