In sectors such as automotive, e-mobility, and electronics, the standards for adhesive bonds are high. A connection must not only be strong and reliable, but it must also be reproducible across hundreds of thousands of units, resistant to vibrations and temperature fluctuations, and increasingly: reversible.
Rework, repair, and recycling are no longer afterthoughts, but design requirements.
Die-cut materials with an adhesive layer and removable tapes such as tesa® 76565 Bond & Detach play a key role in this.
Why precision die-cutting is relevant for large production volumes
For small series, manual cutting of tape is still manageable. For automotive and industrial volumes, that picture changes completely. Any variation in cutting dimensions, positioning, or pressure translates into a variation in bond strength and thus a risk of failure on the line or, worse, in the field. Die-cutting eliminates that variable: every part comes off the press in exactly the same shape and dimension, ready to be applied automatically or manually.
For applications with complex contours, cutouts for connectors, round housings, or multi-layer constructions combining rubber or foam with tape, this is not only a time-saver but often the only feasible way to guarantee consistent quality at scale.
A closer look: tesa® 76565 Bond & Detach
tesa® 76565 is a 500 µm (0.5 mm) double-sided stretch-release tape, composed of a single layer of black synthetic rubber. The dynamic shear resistance is 80 N/cm², both initially and after 3 days at room temperature, indicating that the bond strength remains stable after processing, which is relevant for parts that are tested or loaded later in the process.
The distinguishing feature lies in the stretch-release mechanism: by stretching the tape during disassembly, the adhesive strength drops significantly, and the material releases without residue. No heat, cold, solvents, or additional tools are required. This makes disassembly suitable for manual, machine-assisted, or fully automated processes, and it is applicable throughout the entire lifespan of the product, even after years of use.
Applications in automotive and electronics
tesa positions 76565 specifically for the bonding of high-quality components. Concrete application areas:
- Battery packs (e-mobility): sealing of battery packs and assembly of cells and modules. In the event of a defective cell or module, the pack can be opened and the part replaced without damaging the housing or surrounding components, which is important given the cost and safety requirements surrounding battery systems.
- Displays and ADAS components: permanent mounting during the vehicle’s lifespan, with the possibility of rework in case of production errors or repair in case of defect, without having to replace the screen or sensor.
- Rework during production: when a part is incorrectly positioned or fails a quality check, it can be detached and repositioned instead of being disposed of as waste. This reduces scrap costs and rework time.
- Temporary fixation: during assembly, transport, or testing phases, the tape holds parts firmly in place, to be removed afterwards without tools and without issues.
These properties align with a broader trend in automotive design: components are increasingly designed with the end of the life cycle in mind, focusing on repair, reuse, and recycling.
Die-cutting Bond & Detach adhesive tape: a combined solution
Stretch-release tape such as tesa 76565 is often processed in roll form on the customer’s line for battery modules, sensor housings, or display edges. However, the tape can also be pre-die-cut into customized formats tailored to the application; the customer then receives a ready-to-use part that can be correctly positioned in one movement, without manual trimming on the line.
The combination of both techniques, precision die-cutting and removable bonding, results in an adhesive component that:
- consistently has the same shape and bond area across every production unit;
- offers a predictable, controlled bond strength during use;
- can be released at a controlled moment for maintenance, repair, or recycling, without damage to surrounding parts.
The role of De Kemphaan in this process
De Kemphaan manages the entire process from raw material to ready-to-use component:
- processing of adhesive materials, whether supplied by the customer or not;
- die-cutting or laser cutting tailored to specific application and tolerance requirements;
- assembly and bonding of composite parts;
- packaging into a directly deployable end product for the production line.
For companies in automotive and related industries, this means that the complexity of material choice, cutting technique, and processing is solved externally, while the end result integrates directly into their own production process.
When is this approach relevant?
Precision die-cutting in combination with removable bonding is particularly valuable when:
- parts may need to be disassembled, repaired, or replaced during their lifespan;
- recycling or reuse of components is a requirement;
- consistent bond strength across large volumes is a critical quality factor;
- complex or precise shapes cannot be reproduced manually;
- rework during production must limit costs and material loss.
De Kemphaan collaborates from material selection to the final application to achieve a solution that meets the specific requirements of your production process.
Contact us to discuss your specific application.
