When attaching a roof spoiler in the premium segment, an automobile manufacturer encountered a requirement that quickly pushed a standard solution to its limits:

A self-adhesive molded part had to ensure high holding forces, withstand extreme temperatures, and fit perfectly into the installation space—without additional process steps at Tier 1.

The crucial point: The tear-resistant, fabric tape-reinforced pull tab had to enable final fixation at an unfavorable pull-off angle—without compromising the previous assembly process.

This case study shows how we combined these requirements in a single, series-optimized solution.

We manufactured a total of 20 different self-adhesive items for the roof spoiler assembly for the premium segment of an automobile manufacturer. One component was particularly challenging:

It was used for the final attachment of the spoiler – and therefore had to reliably withstand high loads, tight tolerances, and demanding assembly steps.

• High holding force and temperature resistance
• Precise material thickness for tight installation space
• Black material – invisible integration into the component
• Very stable pull-off function against the adhesive direction

This made it clear that it was not only the material itself, but above all the pull tab that determined the success of the series.

Process-related key requirement: 
A strong but interference-free tab 

The pull tab must not hinder assembly at any point – even though it is crucial for the final fixation.

In addition, it is pulled off in the opposite direction to the adhesive surface. This movement generates strong tensile and
peeling forces that a conventional tab cannot reliably withstand. A seemingly small function – with great process relevance.

Customer process

1. The molded part is removed from the roll.
2. The molded part is applied to the component – the cover liner remains on the molded part.
3. The component is installed in the vehicle line.
4. Only at the OEM is the remaining liner pulled off in the opposite direction and the molded part finally fixed in place.

To ensure smooth installation, it had to be long enough and securely fixed in place, without sticking out or getting caught, and without requiring any additional handling.

A conventional pull tab design or a pull tab that was glued on later would have been disruptive and prone to errors.

A conventional tab design could have gotten stuck or come loose during the first step of the process, directly impacting cycle time and scrap rates. At the same time, the tab had to function reliably under high tensile forces in the opposite direction during the OEM process.

Our solution: a pre-folded tab fixed in a process-neutral manner that only performs its function at the decisive moment.

After punching, the tab is precisely pre-folded and securely fixed to the molded part via a defined adhesive surface. This ensures that it remains completely undisturbed during the first assembly steps – and can be released in a controlled manner during final removal.

To reliably absorb the strong pull-off movement against the adhesive direction, the tab was additionally reinforced with a fabric tape. This ensures that the forces generated are cleanly transferred into the material – even with tight tolerances and demanding component geometries.

The result: error-free assembly, reliable final fixation, stable series production process.

Additional process optimization:
narrower rolls for greater efficiency 

Further potential for optimization became apparent during the course of the project: the rolls were to be hung side by side for assembly. Due to the production of the handling tabs from liner excess, the roll was very wide, but the molded part on it was no longer, as the tabs were subsequently folded and the overall molded part width was reduced.

This meant that only a few rollers could be hung next to each other. They had to be replaced more frequently, interrupting the process. 

Our solution:

• Carrier liner width reduced after punching
• More rolls available at the same time
• Fewer changes during the process
• Less material waste, better ergonomics, and tidier workspace
• An example of how small improvements can have a big impact.