In the automotive industry, there are components which, despite their small size, play a critical role in the efficiency of the assembly process and in the reliability of the final product. This is the case with metal fastening clips: technical parts designed to ensure retention, stability and faster assembly in different areas of the vehicle.
This case study presents the development and production of a metal clip for application in the engine compartment, designed to fasten a radiator return pipe. It is a small part, produced in high-volume series, which demonstrates ETMA’s ability to develop customised, technically rigorous solutions suited to the requirements of the automotive sector.
PROJECT CONTEXT
The project began in 2017, following contact from a client in the automotive sector who was already working with ETMA on the development of another component.
The challenge was to create a non-standard fastening solution, tailored to the specific requirements of the final application. Unlike standard catalogue solutions, this part required a tailor-made response, both in terms of geometry and functionality.
The clip performs two main functions: on the one hand, it enables fastening to a structural area of the chassis, in the engine compartment; on the other, it ensures the housing and retention of a return pipe from the engine cooling circuit, operating as a quick-fit system. The geometry of the part allows the pipe to remain securely locked in place and, when necessary, to be removed by activating the release tab.
This combination of fastening, retention and controlled disassembly makes the component particularly relevant in applications where assembly speed must coexist with functional safety.
A SMALL PART WITH HIGH TECHNICAL DEMANDS
Despite its reduced size, this clip presents significant technical requirements. The part must ensure dimensional stability, suitable elastic behaviour and sufficient resistance to perform its function over time.
As this is a heat-treated part, it was necessary to consider, from the outset, the potential deformation resulting from the process. This factor required careful fine-tuning of both the tool and the production process, in order to ensure that the final part maintained the geometry and functional characteristics defined by the client.
The choice of coating was also an important factor. In this case, a zinc flake solution was used as an alternative to galvanic zinc, as it is a technically more suitable option for heat-treated parts. The objective was to ensure corrosion protection while also avoiding risks associated with electrolytic galvanising in parts with specific mechanical characteristics.
ETMA’S RESPONSE
ETMA’s response was based on an integrated approach, from the initial development stage through to the regular production of the part.
The process began with the manufacture of prototypes, allowing the client to validate the concept and test the functionality of the solution. This stage was essential for introducing adjustments before the final definition of the drawing and the transition to the industrialisation phase.
Once the technical solution had been stabilised, ETMA moved forward with the development of the tool and the definition of the most suitable production process. The part began to be produced through stamping on Bihler equipment, a technology particularly suited to small and medium-sized metal components with technical geometries and a need for high repeatability.
This is precisely one of the areas in which ETMA stands out: the production of technical small and medium-sized parts, in medium and high-volume series, with the ability to respond to specific solutions and not only to standard components.
PRODUCTION PROCESSES INVOLVED
This project demonstrates the importance of ETMA’s system of 10 Integrated Production Processes, making it possible to bring together, in a single industrial response, several critical stages in the development and production of the part.
In the case of this clip, the following processes stand out:
The prototyping stage made it possible to validate the geometry, test the retention function and adjust the solution in collaboration with the client. More than an initial sample, the prototype acted as a technical development and functional validation tool.
Following concept validation, the tool required for series production was developed. This stage was essential to ensure repeatability, dimensional stability and compatibility with the production rates required by the project.
The part is produced on Bihler equipment, a technology suited to the production of technical metal components with high precision and repeatability. This process makes it possible to transform metal strip into a functional part, ready to meet the fast assembly requirements of the automotive sector.
Heat treatment improves the mechanical properties of the part, particularly in terms of hardness and functional behaviour. In this project, this stage was especially relevant, as the deformation associated with the process had to be considered and compensated for throughout production development.
Surface protection was ensured through zinc flake, a suitable solution for increasing corrosion resistance and preserving the technical characteristics of the part. This process contributes to the durability of the component and to its suitability for the requirements of the automotive environment.
Certain critical characteristics of the part are subject to 100% final sorting, ensuring that the points with a direct impact on functional performance are controlled before delivery to the client.
HIGH-VOLUME SERIES PRODUCTION AND LONG-TERM RELATIONSHIP
Since 2017, this clip has been part of ETMA’s regular production, with an approximate annual volume of 1 million parts.
This figure demonstrates not only the robustness of the solution developed, but also ETMA’s ability to support long-term projects, ensuring production stability, technical control and continuity of supply.
The production of this type of component is aligned with ETMA’s positioning as an industrial partner prepared to develop and manufacture small and medium-sized metal parts, in medium and high-volume series, with a strong technical component and high repeatability requirements.
ADDED VALUE FOR THE CLIENT
This project highlights the value of ETMA’s integrated approach in the development of customised metal solutions for series production.
For the client, this approach translates into concrete advantages:
- development of a non-catalogue part, tailored to the specific requirements of the application;
- complete industrial response, supported by the horizontal integration of several production processes within ETMA;
- reduced complexity associated with managing different suppliers;
- greater control over the critical production stages, from tool development through to final inspection;
- improved technical support throughout the entire process;
- optimisation of lead times and costs;
- greater predictability in the transition from development to continuous production;
- consistency and repeatability in high-volume series production.
In the case of this clip, these advantages become particularly relevant: a small, customised and technically demanding part, produced in high-volume series to meet the requirements of the automotive sector over time.
CONCLUSION
This automotive fastening clip demonstrates ETMA’s ability to interpret the client’s need, transforming requirements into rigorous product and process specifications for a customised, robust metal solution ready for high-volume series production.
With several integrated production processes, ETMA ensured a complete and stable response, reinforcing its positioning as an industrial partner for technical small and medium-sized components intended for medium and high-volume series.
Do you have a project that requires a customised technical part, with stable and repeatable production?
ETMA develops tailor-made metal solutions, prepared to meet the demands of the automotive industry and other industrial sectors.