Adhesive Bonding in Automotive Engineering: What Happens If We Miss the Opportunities

When the future of automotive engineering is discussed, the focus is usually on topics such as battery technology, software, autonomous functions or new vehicle platforms. Joining technology rarely plays a leading role in these discussions. Yet it is precisely at the interfaces between materials, functions and processes that it is decided whether many of these innovations are even feasible. In my view, adhesive bonding technology will therefore continue to grow in importance in the coming years. Not because it replaces traditional joining methods, but because it can bring together requirements that can hardly be met by individual technologies or other technologies alone. A key aspect, however, is whether we consistently harness the technological potential and the existing expertise.

Demands are growing – and with them, the importance of adhesive bonding

The transformation of the automotive industry is fundamentally changing the role of joints. In the past, the focus was often on purely mechanical joints. Today, bonded joints often have to fulfil several functions simultaneously.

In modern battery systems, for example, they join different materials, provide the necessary stability, support thermal management, perform sealing functions and contribute to electrical insulation. As a result, the joint itself becomes a functional component of the overall system. This is precisely where I see the greatest necessary shift in users’ mindset: the performance of an adhesive does not determine the success of an application. It never has. What matters is how well materials, surfaces, processes and functions can be integrated into a robust and process-reliable overall system.

Multi-material construction requires new bonds

The trend towards multi-material construction will continue to grow. Aluminium, steel, plastics and fibre-reinforced composites will be combined even more frequently in future to achieve an optimal balance between weight, cost and functionality. These materials have very different properties. They react differently to temperature changes, ageing or mechanical stresses. It is precisely at these interfaces that the greatest challenges arise. Adhesive bonding offers a decisive advantage here: it can compensate for stresses, join different materials and integrate additional functions. This requires a deep understanding of the interactions between material, surface and process. The good news is that we have this understanding.

Batteries turn adhesive technology into a systems challenge

This development is particularly evident in the field of electromobility. New concepts such as ‘cell-to-pack’ or ‘cell-to-chassis’ are changing the requirements for joining technology. Adhesives are no longer used there merely to join components together. They simultaneously perform tasks relating to thermal management, electrical insulation and the protection of sensitive components. That is why we are now increasingly talking about system solutions rather than individual adhesive applications. The real challenge lies in meeting different requirements simultaneously and reliably integrating them into industrial processes. There are plenty of examples to show that we can do this.

Germany is well-positioned

When it comes to future-oriented topics, there is often discussion about Germany’s weaknesses as a business location. In the field of adhesive bonding technology, however, I see a solid foundation.

Germany boasts a unique combination of materials expertise, surface technology, simulation, process development and qualification. Added to this are established norms and standards that make bonding processes predictable and auditable.

People are a key factor in this success. Well-trained specialists are essential for ensuring that complex applications can be implemented safely. That is why qualification programmes and further training are becoming increasingly important. They have led to more and more people in Germany knowing how to bond correctly – regardless of where they are involved in the bonding process.

Can adhesive bonding technology save Germany as an automotive hub?

This question crops up time and again. My answer: No, because no single technology on its own will either bring about the transformation of the industry or automatically restore Germany to the top of the global automotive manufacturing sector. But it can make an important contribution. The strength of German industry has always lain in its ability to understand complex systems and implement them reliably. This is precisely where adhesive technology delivers its greatest benefit. It makes it possible to combine different technologies and to make sophisticated concepts industrially viable. In this way, it becomes an enabler of innovation. In many projects, we see that companies still regard adhesive bonding technology purely as a joining technique and do not fully exploit its potential. We can do more: everything we need is at our disposal. We just need to make use of it and overcome our reservations.

A widespread misconception that I encounter time and again in practice is, for example, that adhesive bonding makes applications more complicated. Our projects and experience show the opposite to be true. What is crucial is taking a holistic view of this joining technology. When used correctly, adhesive bonding reduces complexity for the reasons mentioned earlier. Adhesive bonding processes are now well established. Advances in polymer chemistry, surface pretreatment, automation, simulation and quality assurance enable a high level of process reliability.

The future began long ago

Adhesive bonding is one of the oldest joining technologies in existence. At the same time, it is one of the most dynamic technologies in modern automotive engineering. It supports lightweight construction concepts, enables new material combinations, improves the integration of functions and opens up new avenues for more sustainable products. Developments such as debonding technologies or recycling-friendly adhesive systems show that the industry is also actively addressing future requirements. That is why the crucial question today is no longer whether adhesive bonding should be used. The crucial question is what innovation potential can still be tapped through its targeted use, or rather, which developments we will miss out on if we do not utilise adhesive bonding consistently and professionally. If we miss these opportunities, other markets will be quicker to translate the technologies already available today into industrial value creation. The crucial question is therefore not whether adhesive technology will be part of the transformation, but where the value creation resulting from this transformation will occur in the future. Those who recognise the opportunities at an early stage and understand adhesive bonding technology as part of an overall system can accelerate developments, simplify processes and create competitive advantages. In my view, this is precisely where the great opportunity lies for Germany as an automotive hub.