Micro-composite parts from ZORGE for automotive comfort
What determines the comfort of a modern vehicle? Often, it is not the visible elements, but tiny, hidden high-tech components inside. Our micro-composite parts made of rubber and metal ensure that comfort features such as seat adjustment, massage programmes or lumbar supports function reliably.
Comfort begins in the details
At the heart of many seat comfort systems are valve blocks that activate a wide variety of functions via compressed air control. Crucial to this are valve anchors with integrated rubber seal – tiny rubber-metal connections with high demands and zero margin for error.
They must guarantee consistent sealing performance over millions of switching cycles whilst exhibiting minimal wear. This performance is achieved through precisely matched materials and highly developed manufacturing processes. What may seem self-evident in the comfort segment is the result of complex material and manufacturing processes.
Precision in elastomer processing
Over the past few years, conventional injection moulding has evolved into a high-precision industrial manufacturing technology. Today, tolerances in the hundredths of a millimetre range are achieved in rubber-metal composite parts – meeting the standards of precision engineering and standard automotive requirements for safety- and comfort-critical seat system components.
Crucial to this is a holistic understanding of the process – from material selection and surface pre-treatment through vulcanisation to automated quality testing.
Material expertise as a key to success
The long-term durability of micro-composite parts depends largely on the perfect bond between the elastomer and the metal substrate. Surface activation and modification processes ensure durable bonds and maximum service life – even under highly dynamic loads.
Development is particularly efficient when material design, component geometry and the manufacturing process are optimised at an early stage in collaboration with OEMs and system suppliers!
Automated manufacturing and a zero-defect strategy
Despite comparatively long vulcanisation cycles, micro-composite parts can be manufactured cost-effectively at ZORGE – thanks to optimised process parameters, highly automated series production, moulds with a very high number of cavities, and digital process monitoring.
All components undergo a fully automated 100% inspection using high-resolution camera systems, 3D scanners for geometric inspection and customised measurement systems. Even the smallest deviations are detected and classified according to a defined tolerance catalogue.
Extended in-house production for maximum performance
The use of additional technologies ensures our customers that their products will function reliably in long-term use, with maximum process control and reproducible quality. These include
- High-vacuum plasma coatings to reduce friction and slip-stick effects
- Climate-controlled production areas for sensitive processes
- Dynamic test benches for simulating real-world load profiles
- Automated (cleanroom) packaging according to customer specifications
Development partner for sophisticated micro-composite parts
The demands placed on in-vehicle comfort systems are constantly increasing – as are the requirements for miniaturisation, precision and durability. As a development partner, we support our customers right from the early stages of a project, combining materials expertise, process know-how and automated series production to create integrated solutions for high-precision micro-composite parts. Micro-composite parts from ZORGE remain an invisible yet crucial high-performance component within the overall automotive system.
Because true comfort begins – in the details.
