We developed molded parts made of double-sided adhesive tape for air circulation in the battery floor of an electric vehicle—precisely tailored to the customer's existing application device. By using alternative materials, simplified geometry, and wider grip tabs, we were able to reduce the weight by around

Save 20% on material costs and integrate the process for 9.6 million parts into series production with process reliability.

Fast. Reliable. Economical. From initial sampling to millions of parts.

An automobile manufacturer needed a spacer layer in the battery floor of an electric vehicle to ensure air circulation and thermal stability in the battery housing. The spacing was specified and was to be created by the material thickness of a double-sided adhesive tape.

The plan was to produce 1.2 million battery modules – 8 adhesive tape molded parts per module. That's a total of 9.6 million parts. The application device had already been specified.

The key question was: How can we produce the adhesive tape parts in such a way that they fit optimally into the existing process – and remain economical?

• High volume requirements
• Clear cycle time specifications
• Components must fit the application device precisely
• Air layer must not be compromised
• Lowest possible material and tooling costs

Material selection – not automatically the standard

We suggested several suitable materials and provided samples in different variants. The customer deliberately chose not to go with the standard solution commonly used in the industry, thereby saving approximately 20% in material costs.

Geometry development – precisely tailored to the fixture 

To ensure that the components function perfectly in the customer's process, we tailor everything precisely to their requirements:

• Positioning of parts at the correct distance
• Precise feed of parts for double application
• Defined distance to the side edge

The parts are always manufactured in pairs: 2 molded parts – 1 handle. Ideal for automated removal.

Process optimization – simpler, faster, cheaper

Originally, a partial tab was planned. Our recommendation: it is better to go across the full width.

Advantages:

• Easier handling during removal
• Lower tool complexity
• Better cycle time
• Lower production costs

In addition, we have not implemented any radii. This reduces tool and process complexity—and speeds up production. All in all, it saves costs.

Cost-effectiveness

The conscious choice of materials resulted in savings of around 20 percent in material costs. At the same time, the simplified design reduces tooling costs and enables cost-effective production—even for large quantities.

Process reliability

The molded parts are precisely tailored to the existing application device. The wide grip tab facilitates handling and, together with the double application, ensures a fast, robust, and stable process in series production.