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Exceeding Cost Reduction Target and Minimising Waste

 3M Thinsulate

Asked to help simplify a luggage compartment acoustic pack, 3M used Thinsulate to exceed the cost reduction target while simultaneously minimising waste, simplifying manufacture and improving vehicle refinement.

The Challenge:

Road noise can be a significant issue for off-road and Sport Utility Vehicles (SUVs). A major vehicle manufacturer had successfully addressed this challenge using a sophisticated acoustic pack that included a five piece, self-adhesive polyester wadding set on the inside of each luggage compartment side panel.

Each piece was hand fitted, requiring time to remove the protective backing and position the component, and additional resources to collect and dispose of the backing material. The challenge for 3M was to achieve a significant reduction in cost without compromising refinement or durability.

The Solution:

The flexibility of 3M’s Thinsulate allowed a single part solution to be developed for each side, considerably simplifying installation. The use of ultrasonic welding eliminated the need for an adhesive layer with a protective backing element, removing the waste collection and disposal issues.

Tests showed that like-for-like substitution provided a significant improvement in refinement. This allowed further cost and weight savings to be achieved by part size reduction and optimisation of the component shape to increase material yield.

The final design delivered equivalent acoustic performance to the five part system, but with superior durability, easier end-of-life recovery and reductions in weight, component cost, process complexity and waste.

Benefits of 3M Thinsulate

Weight reduction – weight can be reduced with no reduction in performance, when compared with felt, foam and polyester materials.

Effective isolation – 3M Thinsulate is easy to compress, allowing simple installation in small cavities that maximises effectiveness by placing the material close to the noise source.

Reduced production costs – as less material is required, production and logistics processes can be simplified and less line-side space is required.

Durable – non-woven structure allows both internal and external use without the need for additional waterproofing.

Waste reduction – can be mechanically attached or fitted using ultrasonic welding, eliminating the need for adhesives and for backing material that must be collected and disposed of

Easily recycled – polypropylene blend simplifies end-of-life recovery.


  • Interior acoustic packs,
  • In-door acoustic packs,
  • Under-bonnet acoustic packs,
  • Wheel arch liners,
  • HVAC isolation.

Challenge us to save you money

Let 3M undertake a line-walk review with you to identify material cost and efficiency improvements. Thinsulate is well proven and our specialists can demonstrate other manufacturing and cost reduction benefits.

Contact Us to put us to the test!



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