Automotive Industry

Automotive bonding, sealing and protection

Automotive applications we support

Automotive industry challenges

Adhesives, Sealants and Tapes for Motorsport

Automotive adhesive and tape applications

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Bonding mixed materials

Vehicle designers increasingly combine metals, composites, glass and engineered plastics within the same assembly. Differences in thermal expansion, stiffness and surface energy can place additional stress on a joint.

Flexible adhesives, structural epoxies, acrylics, silicones and acrylic foam tapes each behave differently. We review the substrate combination, bond area and expected movement before recommending a material.

Reducing vehicle weight

Adhesives and tapes can reduce the use of selected screws, rivets, clips and welded attachments. They can also spread stress across a wider bond area, support the use of thinner materials and avoid holes through panels.

Any fastener replacement needs to be assessed against the actual load, joint geometry, environmental exposure and required safety factor. We can help identify suitable candidates for trials and validation.

Faster automotive assembly

Production speed depends on more than cure time. Material handling, surface preparation, dispensing, fixturing and the time before a component can be moved all influence line speed.

Pressure-sensitive tapes provide immediate handling strength. UV-curing adhesives can cure in seconds where the joint and material allow light to reach the adhesive. Heat-cured, dual cured, part-cured, and moisture-cured systems suit other processes; the correct choice depends on the assembly.

Heat in electric and connected vehicles

Battery systems, ECUs, inverters, charging hardware, sensors and LED lighting all generate heat. Air gaps between a component and its heat sink restrict heat transfer, so designers use thermal interface materials to fill surface irregularities and create a more effective thermal path.

The required thermal conductivity is only one part of the decision. Bond-line thickness, hardness, flow, electrical behaviour, repairability and dispensing method also need to be considered.

Protecting automotive electronics

Automotive electronics can face moisture, condensation, dust, vibration, mechanical shock and wide changes in temperature. Potting compounds, encapsulants, conformal coatings and silicone adhesive sealants can protect components and connections from these conditions.

The level of protection required will depend on the component, housing, service environment and production process.

Maintaining a consistent supply

Automotive programmes need dependable materials, controlled storage and clear documentation. We support repeat production through forecast-based stock management, call-off orders, specialist storage, kitting, repacking and custom labelling.

Vehicle body, panel and structural bonding

Structural adhesives can bond metals, composites and selected plastics across body components, brackets, housings and sub-assemblies. Epoxy, acrylic, methacrylate, polyurethane and hybrid polymer systems are available, with different levels of strength, flexibility, gap filling and environmental resistance.

Acrylic foam tapes can also be used for suitable semi-structural and attachment applications. Their viscoelastic core helps accommodate movement and distribute stress along the bond line.

Products and ranges to consider:

• 3M 5952 VHB Acrylic Foam Tape
• Automotive panel bonding products
• Structural adhesives

Exterior trim, badges and body-side mouldings

Automotive exterior attachment tapes are used for body-side mouldings, cladding, wheel arch components, roof ditch mouldings, badges and other decorative or protective parts.

The tape must suit the component substrate and the vehicle paint system, while also handling water, cleaning chemicals, vibration, cold impact and temperature change.

3M PT1100 VHB Acrylic Plus Tape is designed for automotive exterior trim attachment. Typical applications listed for the range include body-side mouldings, cladding, roof ditch mouldings and wheel flares.

Through our sister company, Viking Tapes, we can also supply automotive exterior mounting tapes in standard widths or discuss converted formats for repeat production.

Automotive interiors and trim bonding

Vehicle interiors contain plastics, textiles, foams, leather, coated fabrics and decorative surfaces. Bonding applications include door cards, instrument panels, centre consoles, headliners, carpets, seat components, insulation and interior trim.

Double-sided tapes provide immediate handling strength and can reduce visible fixings. Liquid adhesives and hot melts may be more appropriate for complex shapes, porous materials or larger surface areas.

3M GPT-020F Double-Sided Tape uses an acrylic adhesive with a polyester carrier and is suitable for a range of high and low surface-energy plastics. Other double-sided tapes for automotive interiors are available where a different thickness, carrier or adhesive system is required.

Low-odour and low-VOC options can be considered where the vehicle interior specification requires them. These requirements must be checked at individual product level.

Displays, control panels and HMI assembly

Touchscreens, displays, control panels and other human-machine interface components require accurate bonding around thin substrates and restricted bond areas.

Depending on the design, suitable materials may include optically clear adhesives, double-sided tapes, UV-curing adhesives, silicones and electronic-grade sealants. Selection may be influenced by optical performance, touch sensitivity, thermal expansion, vibration and the need to avoid stress around the display.

For serviceable control panels and covers, reclosable fastening systems such as 3M Dual Lock SJ3550 can provide secure attachment with repeat access.

Noise, vibration and harshness control

Vehicle panels, equipment housings and interior components can transmit vibration and generate unwanted noise. Pressure-sensitive damping materials convert a proportion of this vibration into low-level heat, reducing resonance through the treated panel.

3M 435 Vibration Damping Tape combines a soft aluminium constraining layer with a viscoelastic polymer. It is designed to absorb and dissipate vibration, helping to reduce noise and fatigue.

Foam tapes, cushioning materials and bonded insulation can also be considered for rattles, buzz, vibration isolation and acoustic control.

Powertrain, engine and transmission sealing

Automotive powertrain components need reliable sealing against engine oil, transmission fluids, coolant, water and other chemicals. Joint movement, vibration, flange condition and pressure testing can place further demands on the seal.

Liquid gaskets and form-in-place gaskets can follow complex flange geometry and avoid the handling associated with pre-cut gaskets.

ThreeBond TB1215 Grey OEM Engine Gasket is an automotive RTV silicone liquid gasket designed for flange sealing applications such as gear cases, oil pans and valve covers. It offers resistance to gear oil and mechanical shear, subject to the conditions stated in its technical data.

Our ThreeBond powertrain guide also covers TB1217H, TB1207B and TB1184 for different engine, transmission and flange-sealing requirements.

EV battery module and battery pack assembly

Electric vehicle battery systems use adhesives and sealants for cell contacting systems, module assembly, thermal transfer, electrical insulation, environmental sealing and electronic protection.

The material may need to provide one or more of the following:

• Thermal conductivity
• Electrical insulation or electrical conductivity
• Gap filling
• Structural support
• Vibration protection
• Resistance to moisture and automotive fluids
• Controlled hardness to limit stress on cells or electronics
• Flame-retardant performance
• Compatibility with automated dispensing and curing

Our guide to adhesives for cell contacting systems and battery pack assembly covers Panacol UV-curing and dual-curing adhesive systems developed for these applications.

Material approvals, flammability ratings and electrical properties should always be confirmed against the exact grade and battery design.

Thermal management for EVs and automotive electronics

We supply thermally conductive adhesives, gap fillers, potting compounds, greases and liquid-dispensed thermal pads for batteries, ECUs, power electronics, inverters, charging systems, sensors and vehicle lighting.

TECHSiL TIM11123GB is a one-part, self-gapping thermally conductive RTV silicone with a published thermal conductivity of approximately 2.3 W/m.K. Glass beads control the bond-line thickness and the material is supplied in a 310 ml cartridge.

Momentive SilCool materials include thermal adhesives, encapsulants, potting compounds, greases and liquid-dispensed gap fillers. Our advanced thermal silicones for EV and AV applications guide covers examples including TIA225GF, TIA208R, TIA241GF and TN8000.

View our thermal management knowledge base

ECUs, connectors, sensors and electronic modules

Potting and encapsulation materials surround an electronic assembly, helping protect it from moisture, contaminants, vibration and mechanical stress. Silicone, polyurethane and epoxy materials offer different combinations of hardness, flexibility, adhesion, thermal behaviour and chemical resistance.

Flexible silicone materials can be useful where delicate components, thermal cycling or vibration create a need for lower stress. Harder encapsulants may suit applications requiring greater mechanical protection.

Momentive RTV133 Electrical Silicone is a one-component black silicone adhesive sealant intended for electronic and automotive applications where low flammability is a design consideration. Any UL rating must be checked against the product specification and the proposed application.

Read our guide to potting electronic components

ADAS, cameras and LiDAR assemblies

ADAS cameras, LiDAR systems, sensors and their control electronics require stable positioning and protection from heat, moisture, vibration and contamination. The small bond areas used in these assemblies can also make controlled dispensing and cure particularly important.

Potential material groups include:

• Low-stress silicones for camera and sensor components
• Thermal materials for control units
• Potting and coating materials
• UV-curing adhesives for rapid component fixation
• Sealants for housings and optical assemblies
• Electrically conductive or shielding materials where specified

Our material solutions for LiDAR assemblies guide covers Momentive SilCool thermal materials and SnapSil electronics bonding materials for automotive sensor systems.

Automotive masking and surface protection

Paint preparation, refinishing and component manufacture require tapes that can follow curves, resist the relevant bake temperature and remove without damaging the surface or leaving unwanted residue.

3M 3434 Blue Automotive Masking Tape is a smooth creped-paper tape intended for automotive masking applications. Viking Tapes also supplies fine-line tapes, foam masking, protective films and low-bake masking grades.

View automotive masking tapes

Wire harnessing, insulation and cable protection

Automotive wire harness tapes are used for bundling, abrasion protection, noise reduction, electrical insulation and local reinforcement. Product selection depends on the harness location, temperature, abrasion risk, flexibility, noise requirement and relevant OEM specification.

Our sister company, Viking Tapes, supplies electrical, cloth, film and specialist tapes in a wide range of widths. We can help identify appropriate products and supply slit widths for repeat harness production.

View automotive tapes and production materials