Our customer’s need was to make his sunroof movement system more flexible, lightweight and silent. A really difficult challenge, that of modifying an already consolidated system in the automotive industry, where the majority of innovations are easily rejected or – if they are applied – they definitely revolutionize the market.
The drive structures for Bowden cables used in the handling of sunroofs are made through the use of stainless steel pipes, these have the disadvantage of being noisy because of the movement of the cable that runs inside, heavy and expensive because of the use of steel and its welding, bending and mechanical processing.
To overcome these problems, for our customer we have designed, patented and implemented a more flexible multimaterial drive system – with replacement of the metal tube with a new moulded tube made of technical polymers – which is able to guarantee lightweight and flexibility required by the assembly process and the stiffness necessary for moving cables and for the stability of the whole mechanism.
The best performance of each material selected and assembled.Explore
Manual and automated tests, process controls and production tests.
Automated departments, over 30 presses, working 24 hours a day 365 days a year.Explore
Accuracy, speed and variability in machining complex parts.Explore
Manual and automatic assembly required by the complexity and versatility of the components.
- System flexibility
- The system we have developed guarantees perfect assembly thanks to the shape memory of plastic materials.
- Weight reduction
- The use of plastic extrusions and technical polymers has allowed us to obtain a structure that is much lighter and easier to manage.
- Noise reduction
- The use of plastic extrusions and technical polymers has allowed us to obtain a much quieter structure in the opening and closing phase of the sunroof.
- Cost cutting
- The optimization of the production process has made possible a significant reduction in costs compared to the standard on the market. Less investment, less work, less accessories: a unique integrated product of its kind.
Structural lightening with the replacement of metal pipes with tubes in technical polymers
Savings on the market standard thanks to the fully optimized process.
Noise reduction compared to the systems which use metal pipes.
Customer satisfaction with the solution we developed as an alternative to standard systems.