From Two Components to One – Reducing Material by 50% and Improving Assembly Efficiency

MultiMaterial-Welding AG develops innovative joining solutions for lightweight materials. Using MM WELDING^® technology, thermoplastics are embedded by ultrasound directly into textile and fibrous materials, creating strong and reliable joints without adhesives or additional fastening elements. Lotus Abalone applies this principle to automotive interiors. The one-piece eyelet is integrated directly into the vehicle carpet, combining carpet attachment and floor mat retention in a single component (see image). Compared to conventional two-piece solutions, material consumption is reduced from 16 g to 8 g per component while maintaining the same load-bearing performance. Fewer parts, lower material usage, and a fast, fully automated assembly process increase efficiency throughout the entire manufacturing chain. The solution is production-ready and already in use by leading automotive manufacturers.