As a result of R&D work, in June 2020 Fabryka Maszyn Lubaczów Sp. z o.o. completed the implementation of an investment project that enabled the extension of its product and service portfolio to include the manufacturing of a contoured base for the tool cassette of an infrared welding and/or ultrasonic welding device used for automotive interior components. These may include, for example, complete dashboard elements, inner door panels, instrument panels, and similar components.

Vehicle interior components are typically made of thermoplastics. Their individual parts are joined by infrared or ultrasonic welding. The contoured base of the tool cassette used in the welding device for these components—especially dashboard elements—consists of four to six segments that adjoin one another along their side surfaces. Each segment has a smaller volume than the entire contoured base and is equipped with mounting features that position the assembled segments to form a complete contoured base.

Advantages of the implemented product:

  • reduced labour intensity and material consumption due to manufacturing smaller component segments instead of a single-piece base,
  • the segmented contoured base allows for the replacement of individual segments in the event of detected defects, welding tool repairs, or design adjustments related to vehicle interior component facelifts,
  • by replacing a segment, it is possible to produce different versions of plastic components,
  • handling smaller segments is more convenient and safer during the tool manufacturing process.