Adler Pelzer Group, a global leader in automotive interior systems, set a new standard for efficiency and design by adopting Bossard’s MultiMaterial-Welding® technology for the Volkswagen ID. Buzz project. The collaboration resulted in a smarter, stronger, and more cost-effective method of connecting functional components within the vehicle’s carpet system.
The Challenge: Reliable Fastening for Soft Materials
Adler Pelzer was tasked with producing the interior carpet system for the Volkswagen ID. Buzz, including ventilation openings. The first approach — directly cutting the holes and using a two-piece clip to attach the ventilation grid — proved unreliable. The carpet’s flexible nature allowed it to move in multiple directions, leading to failed connections.
To overcome this, the team needed a fastening solution that could handle soft, textile-like materials while offering durability, aesthetic appeal, and manufacturing efficiency.
The Turning Point: Reintroducing MultiMaterial-Welding®
Having previously worked with Bossard and being familiar with the potential of MultiMaterial-Welding® (MM-Welding®), Adler Pelzer’s engineering team saw an opportunity to apply it to this challenge. In early 2023, they reached out to Bossard with a simple request:
“We have a project where we need MultiMaterial-Welding.”
Together, the teams began testing the integration of LiteWWeight® Lotus Functionally Integrated Parts (FIP) — an innovative solution that can be embedded directly into injection-molded components. This approach simplified production, reduced cost, and offered new design freedom.
Testing and Validation
To confirm feasibility, two rounds of testing were conducted:
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Moisture testing: Welding was tested on a wet carpet, simulating conditions after waterjet trimming.
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Full-scale prototype testing: SLS-printed prototypes were welded into carpet sections installed in actual test vehicles for OEM evaluation.
The results validated the technology’s strength, precision, and reliability. Integrating the LiteWWeight® Lotus geometry with the plastic ventilation grid enabled rapid one-sided welding using an ultrasonic machine — creating a strong, uniform connection within seconds.
The Technology Behind the Solution
The process involves partial liquefaction of the Lotus teeth, allowing them to anchor firmly into the carpet’s fibrous structure. This results in a permanent, high-strength bond between the textile and plastic components.
The outcome:
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Cycle times reduced dramatically due to one-sided assembly
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50% fewer parts needed, reducing cost and overall weight
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Improved design flexibility and enhanced visual quality
From Prototype to Production Success
With strong test results and excellent visual appeal, the solution quickly gained approval for full-scale use. Initially planned for the 6- and 7-seater variants of the Volkswagen ID. Buzz, the OEM later extended the application to the 5-seater version, increasing production volume by 40%.
“We’ve known about MM-Welding® for a while, yet we were impressed by how effectively the team applied it to our challenge,” said Elmedina Andelija, Key Account Manager at Adler Pelzer Group.
“It not only solved our technical issue but also improved aesthetics and efficiency — a truly successful collaboration.”
Customer Benefits
Proven reliability:
A durable, one-sided welding method that delivers strong, consistent fastening in soft materials.
Efficient production:
Reduced cycle time, lower part count, and cost savings through simplified assembly.
Improved design flexibility:
Functionally integrated components offer freedom in form and finish.
Enhanced appearance:
The streamlined process results in cleaner, more refined interior surfaces.
Setting a New Standard
Through close collaboration and engineering expertise, Adler Pelzer Group and Bossard established a new benchmark for carpet assembly in automotive interiors. The success of the Volkswagen ID. Buzz project demonstrates how MultiMaterial-Welding® technology continues to drive innovation, efficiency, and quality in vehicle design and production.