A plastic attachment on the roof edge spoiler had 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 customized adhesive tape assembly in which all five 

Adhesive tape molded parts on a common liner – with positioning aids, handling tabs, and optimized presentation. The result: 70% time savings and a stable, reproducible assembly process. Learn how a well-designed presentation simplifies complex bonding in our case study.

An automotive supplier was looking for a solution for bonding a so-called aerofin – a plastic component on the roof edge side spoiler. Five narrow webs had to be bonded simultaneously and precisely positioned. The previous supplier solved this with individual parts for each web. In order to remove the liner in one step after bonding, so-called liner bridges were placed between the individual parts.

This solution was inexpensive in terms of materials, but involved enormous effort and a high potential for errors. For example, the liner bridges often did not hold and did not reliably pull off the second liner, which regularly led to process interruptions.

Challenges

• Time-consuming preparation with individual parts and liner bridges
• Unreliable material bonding – process interruptions on the line
• Lack of repeat accuracy during bonding
• High time and personnel costs 

Objective
The company was looking for a process-stable, efficient, and easy-to-install solution that would allow all adhesive tapes to be positioned and processed in a single step.

Instead of continuing to process the five strips as individual parts, we developed a completely new adhesive tape assembly that combines the individual elements on a common liner. 

Specifically, this means: All five adhesive tape molded parts are positioned at the exact required distance from each other on a liner, covered with a second continuous liner, and have protruding areas on both sides that serve as grip tabs.

This allows the entire adhesive set to be positioned in a single step without having to remove or readjust individual parts. The first liner is removed, the component is positioned precisely, and then the second liner is removed – done.

Additional optimizations 
For precise alignment, we integrated laser slots and optical markings that clearly define the positioning of the adhesive tape. This not only speeds up assembly, but also makes it more reliable and ergonomic.

What used to take more than a minute can now be done in 15 to 20 seconds—with consistent quality and minimal risk of error.

The solution was immediately convincing: what used to be complex and prone to errors is now glued in one go – stable, efficient, and reproducible.

Due to its success, the concept was immediately transferred to another vehicle model. Incidentally, it took less than six months from parts analysis to the finished solution.

At a glance

• 70% time savings in the assembly process
• high process reliability and repeatability
• customizable design for additional components and models
• transferable to similar applications

1. Distance pad with tear-resistant liner

This pad is only removed after the part has been installed and prevents rattling noises or visible gaps. Even with varying contact pressure, it ensures a clean, tight connection – the gap remains visually closed (black finish).

2. Protective film for the PMMA outer shell 

To protect the sensitive surface during transport and installation, a special film contour was developed that precisely follows the shape and curvature of the component. 
The film is only removed at the dealership.