How Compression Limiters Drive Innovation In OEM Design

As the demands for durability, precision, and weight savings in automotive manufacturing grow, OEMs are seeking reliable, high-performance components.

The drive for reduced weight in vehicles and the growth in plastic components has set compression limiters up as the go-to fastener of choice. These non-threaded inserts are engineered to protect the plastic and rubber parts that have become so common in modern vehicles, shielding them from the stresses caused by the tightening of bolts.

Find out more about the pivotal role these fasteners play in design and manufacturing in the automotive industry.

Weight Savings Drive OEMs to Choose Compression Limiters

To reduce vehicle weight and enhance fuel efficiency, many metal parts are being replaced with plastic. However, these lighter plastic components still need to be securely fastened to prevent crushing, cracking, or splitting under pressure.

Whenever plastic components are attached to a vehicle with bolts or screws—such as in airbag assemblies, electronic modules, bumpers, fuel pedal assemblies, oil pans, manifolds, water pumps, or valve covers—there is risk of damage. The pressure exerted by tightening can exceed the plastic’s surface tolerance, potentially causing immediate damage or leading to gradual wear that may result in failure over time.

As plastic parts become increasingly common in manufacturing, OEMs need a solution to ensure their protection. Compression limiters are that solution, providing the protection necessary to safeguard plastic components against cracking or crushing.

By allowing OEMs to use plastic parts without compromising structural integrity, these limiters help reduce overall vehicle weight, which in turn improves fuel efficiency and performance.

Cost Savings Add Up

Compression limiters provide significant cost advantages over other fastening solutions, particularly in high-volume production runs. An efficient manufacturing process and optimized design reduce material waste and production time, making them more affordable to produce.

In addition to their lower production costs, compression limiters eliminate the need for more costly parts.

They can hold length tolerance of +/- 0.05mm and are thinner than cut-tube limiters as the grain of the split limiters is 90 degrees different, which increases the strength with a thinner wall for even greater weight and cost savings.

Their streamlined design ensures that they are easy to integrate into assembly lines, reducing labor costs and minimizing errors during installation.

Application-Specific Design

Vogelsang compression limiters are meticulously engineered to meet the unique needs of each application. Unlike other common solutions, they are designed with precision, ensuring optimal performance and protection for every type of plastic or rubber component used across the automotive industry.

Fabricated wholly in compliance with our customers’ application needs, they offer one of the broadest ranges of customizations and benefits among fastening solutions.

We arrange the geometry and the material along with you, including outer diameter, inner diameter, material thickness, length, and the installation aids required, such as bevels, grooves, knurling, flanges, chamfers, internal/external closed slots, and protrusions.

Almost every geometric shape can be implemented, including round, square, rectangle, oval, and triangle.

This application-specific approach is particularly important in automotive manufacturing, where precision is critical.

Why Choose Vogelsang Compression Limiters?

Vogelsang’s compression limiters are specifically engineered for large-scale production runs, providing OEMs with exceptional quality, cost efficiency, and design flexibility. These are some of the reasons OEMs choose our fasteners.

• Manufactured to exacting standards: Precision is paramount in automotive assemblies. Vogelsang’s compression limiters ensure consistency and reliability.
• In-house slitting: Our in-house slitting capabilities enhance both cost-effectiveness and quality control. By managing this process internally, we ensure that each piece meets strict quality standards and the precise height requirements of the application.
• In-house profiling: To improve application efficiency, we also performs profiling in-house, which allows for customized features such as flanges, knurls, and other retention features that aid in faster, more reliable assembly.
  Wide range of material choices: Vogelsang offers compression limiters in various grades of steel, from high-carbon spring steel to low-carbon unhardened steel, allowing customers to choose materials that best fit their application’s needs.
• Made with high-quality German steel: Vogelsang’s compression limiters are manufactured with high-grade German steel and are durable, reliable, and optimized for performance in demanding environments.
• Precision engineering: The metal height is engineered to be slightly higher than the surrounding plastic, ensuring that during bolting, contact is strictly metal-to-metal, safeguarding the plastic from compressive forces and extending the lifespan of the assembly.
• Rigorous sorting and packing: To maintain quality, Vogelsang employs an independent third party for 100% optical sorting and packing. This process guarantees that there are no foreign materials or incorrect products, so these components are ready for high-speed automatic lines.
• TS 16949 Certification: Vogelsang’s TS 16949 certification underscores its commitment to quality in automotive manufacturing, meeting the rigorous standards required by OEMs in the industry.

Ordering Made Easy

At Vogelsang, we understand that OEMs need solutions that are as flexible as they are robust. Whether you need a fastening solution for an existing application or are designing something wholly new, our product specialists will work with you to produce the precise part you need.

With complimentary engineering consulting, we ensure that these components have the features and benefits you need.

When assisting you in selecting or designing a compression limiter, we carefully consider various factors, including the type of plastics used, corrosion resistance needs, installation methods, shrinkage rate, edge spacing, screw size, and other relevant specifications.

With excellent stocking and release programs, Vogelsang is well-prepared to meet customer forecasts and ramp up production as needed, accommodating increased demand over the course of a product’s lifecycle.

We are currently in the process of reshoring compression limiter production to the United States, ensuring faster lead times and expanded availability for domestic customers.

For streamlined order processing, Vogelsang offers EDI capabilities, making it easy for OEMs to integrate orders directly into their systems, reducing lead times and simplifying the purchasing process.

Our commitment to quality, efficiency, and service excellence ensures that your ordering process is simple and efficient so you can focus on building reliable, high-performance products.

To learn more, connect with a Vogelsang representative at (800) 526-2376 or contact us online and discover how we can help drive the success of your next project.