Production of car mats step by step- things to consider.
Creating aesthetically pleasing, comfortable and functional car mats requires specialized machinery. In a time when they constitute an important piece of equipment, it is necessary to take care not only of their functional properties, but also of their appearance or compliance with ecological trends.
Car mats, until recently, were seen as minor and unimportant accessories with marginal significance for the vehicle. However, today they have an impact on the visual perception of the car’s interior and the driver’s comfort. They must effectively absorb moisture carried inside the vehicle on shoes. In this context, it’s worth noting that the incorrect quality of floor mats – such as those made from inferior materials – can directly lead to a greater risk of corrosion.
For a very long time, the market was dominated by two simple models: rubber floor mats and those made of textiles. This situation changed with the advancements in polymer technology. Thanks to this technology and the possibilities of synthetic materials, the automotive industry became acquainted with floor mats made of this type of plastic. The material is characterized by high strength, lack of smell, water and fire resistance. Simultaneously, its structure effectively prevents dirt and moisture.
Undoubtedly, the most influential factor on the proper performance of car mats is the technology of their manufacture, encompassing the tightness of the welds.
How are car mats manufactured
The initial stage is the design phase. Based on the parameters of the car, we can develop a floor mat that fits the space under feet. While in most cases these are universal models, there are also cars with unusual design which require precise sizing of the floor mat.
With the design prepared, we can proceed to the next stage of the process. A sheet of plastic – whether rubber, textile, or the aforementioned polymer – is cut into the shape of the desired floor mats. This is achieved using a precise cutting knife.
After preparing the base layer, we can proceed to the next step – cutting out the patterns and taking care of the edges. These should be prepared in advance to ensure a perfect fit with the main part of the car mat. The edges must be positioned on the material not only for a finishing touch but also to protect the base material from stretching or mechanical damage.
The final stage of car mat preparation involves installing specialized fixings that hold the product in a specific position or location. We can use various technologies here – from Velcro and hooks mounted to the floor, to universal eyelets or mounting elements integrated with the floor. Among other things, at this stage of production, it is crucial to use appropriate machinery that, for example, enables the installation of the correct fastening eyelets.
Quaity car mats – what does it mean?
When examining the production parameters of car mats, we can identify several key features regardless of the chosen material. First of all, they must maintain full water resistance- and therefore be equipped with a waterproof bottom that remains impervious to moisture. Another critical aspect is the product’s slip resistance. It must be secured in such a way that, through the use of Velcro or clips, it prevents it from moving within the car. While driving, this movement could potentially lead to a loss of control over the vehicle. Manufacturers also often opt for adding a special structure to the bottom of the mats to reduce slippage.
Another issue is the ease of cleaning the mats. The bristle used in the top layer should, on the one hand, take in moisture and dirt, while also being short enough to facilitate hassle-free maintenance.
Naturally the structure of the car mats themselves is also important. They should be perfectly tailored to the specific model. This underscores the importance of the custom design phase.
What machines are needed for car mat production?
Depending on the specifics of a given project, both equipment providing high-frequency welding and, for example, eyelet machines will be required to prepare the appropriate fasteners. However, undoubtedly, it’s the former that plays a crucial role in achieving the desired outcome. Modern high-frequency welding machines, like Zemat Signa Duo, ensure the seamless joining of large parts with non-standard structures. This is especially important in the case of high-volume production. Another important consideration is personalization, a desirable feature in the automotive industry. For instance, logos or other markings can be introduced to enhance the car’s uniqueness and its accessories.
Zemat machines offer more than just logo generation or markings – they enable specialized formatting of floor mats. This allows for the creation of customized foot pads or reinforcements precisely where the driver rests their heel. In this way, the mat is protected against potential damage from prolonged leg pressure.