Ultrasonic MM-Welding®: The Future of Interior Solutions
For decades, interior component assembly relied on time-consuming, multi-step joining methods: bolting, riveting, welding, soldering, and brazing. While these techniques remain common, today’s manufacturing demands more: faster production, lighter materials, smarter processes, and reduced costs. Enter MM-Welding®—Bossard’s game-changing ultrasonic technology that’s redefining how interior solutions are engineered and assembled.
MM-Welding® is an ultrasonic, friction-based joining technology that eliminates the inefficiencies of conventional methods. It creates strong, high-repeatability bonds between dissimilar materials—from metals and composites to plastics and porous materials like Expanded Polypropylene (EPP)—without the need for pre-drilling, fasteners, or adhesives.
Why Conventional Fastening No Longer Fits Today’s Interiors
Interior applications, especially in automotive, aerospace, and consumer goods, are increasingly using lightweight, multi-material assemblies. Traditional fastening methods often struggle in these environments due to:
- Manual complexity and long cycle times
- Inconsistent quality and human error
- Material damage or misalignment
- High cost of labor and tooling
- Limited compatibility with dissimilar or porous materials
As products become more complex, compact, and material-diverse, a single-step, AI-driven, clean joining method like MM-Welding® offers unmatched performance and scalability.
What Is MM-Welding® Technology?
Developed through a joint venture between Bossard Group and SKion GmbH, MM-Welding® is a smart ultrasonic joining system. It uses friction and ultrasonic energy to create form-fit, high-strength bonds in seconds without damaging the materials.
The system consists of several stand-alone or integrated machines, each powered by AI-enabled smart software for precision joining, real-time quality control, and rapid prototyping.
Key Advantages:
- Ultrasonic welding of dissimilar materials
- No adhesives, screws, or pre-holes required
- Lower cost and shorter cycle times
- Error-free and repeatable results
- Fully digitized and Industry 4.0 ready
Applications in Interior Solutions: EPP Bonding
One of the most exciting applications of MM-Welding® is in bonding Expanded Polypropylene (EPP)—a material widely used in car interiors, trunk liners, acoustic panels, and floor insulation.
Why EPP?
- Lightweight and impact-resistant
- 100% recyclable and water-resistant
- Excellent thermal and sound insulation
- Strong strength-to-weight ratio
Traditional bonding of EPP requires adhesives, pressure fittings, and multiple fasteners, resulting in longer assembly times, higher material costs, and lower reliability. MM-Welding® replaces this with one efficient, clean, and fully repeatable ultrasonic process.
Inside the MM-Welding® System Lineup
Bossard’s MM-Welding® technology is available in several machine configurations to meet different production needs:
Table-Top Machine
- Compact, manually controlled
- Ideal for low-volume or prototyping applications
- Operated via hand or foot switch
X-Y-Portal Machine
- Automated bonding at multiple points
- Great for medium-volume production
- Programmable clamping and nesting
Dedicated Machine
- High-volume, low-cycle bonding
- Supports complex geometries and part shapes
- Customizable with turntables and multi-angle operation
Robotic Machine
- Full integration with production lines
- High throughput and minimal human intervention
- Real-time production data, minimal adjustments
Each machine is designed for flexibility, durability, and smart manufacturing, leveraging AI, real-time data, and digital process control to create high-performance interior assemblies faster and with fewer errors.
MM-Welding® in Smart Manufacturing
As more manufacturers adopt Industry 4.0 practices, MM-Welding® provides a future-ready solution:
- Shorter design-to-production cycles
- Improved first-time quality (FTQ)
- Built-in process monitoring and QC
- No post-processing or cleanup
- Support for simulations and prototyping
With its ability to adapt to any fixture, shape, or material, MM-Welding® bridges the gap between new design freedom and production efficiency, making it perfect for automotive interiors, consumer electronics, appliance housings, and more.
Why Bossard?
Bossard continues to push the limits of what's possible in fastening and joining solutions. As a recognized global leader in engineering support, logistics systems, and fastening technologies, Bossard brings over 180 years of experience to solving the toughest manufacturing challenges.
The MM-Welding® System is another milestone in Bossard’s mission to deliver smarter, faster, and more sustainable solutions to today’s manufacturers.
Ready to Upgrade Your Interior Assembly Process?
If you're looking to eliminate manual errors, reduce costs, and unlock design freedom with multi-material assemblies, MM-Welding® is your next move.
Contact Bossard today to explore how ultrasonic MM-Welding® can revolutionize your interior applications.