For a very long time, the market was dominated by two simple models: rubber floor mats and those made of textiles. This situation changed with the advancements in polymer technology. Thanks to this technology and the possibilities of synthetic materials, the automotive industry became acquainted with floor mats made of this type of plastic. The material is characterized by high strength, lack of smell, water and fire resistance. Simultaneously, its structure effectively prevents dirt and moisture. Undoubtedly, the most influential factor on the proper performance of car mats is the technology of their manufacture, encompassing the tightness of the welds.The initial stage is the design phase. Based on the parameters of the car, we can develop a floor mat that fits the space under feet. While in most cases these are universal models, there are also cars with unusual design which require precise sizing of the floor mat. With the design prepared, we can proceed to the next stage of the process. A sheet of plastic – whether rubber, textile, or the aforementioned polymer – is cut into the shape of the desired floor mats. This is achieved using a precise cutting knife. After preparing the base layer, we can proceed to the next step – cutting out the patterns and taking care of the edges. These should be prepared in advance to ensure a perfect fit with the main part of the car mat. The edges must be positioned on the material not only for a finishing touch but also to protect the base material from stretching or mechanical damage. The final stage of car mat preparation involves installing specialized fixings that hold the product in a specific position or location. We can use various technologies here – from Velcro and hooks mounted to the floor, to universal eyelets or mounting elements integrated with the floor. Among other things, at this stage of production, it is crucial to use appropriate machinery that, for example, enables the installation of the correct fastening eyelets.When examining the production parameters of car mats, we can identify several key features regardless of the chosen material. First of all, they must maintain full water resistance- and therefore be equipped with a waterproof bottom that remains impervious to moisture. Another critical aspect is the product’s slip resistance. It must be secured in such a way that, through the use of Velcro or clips, it prevents it from moving within the car. While driving, this movement could potentially lead to a loss of control over the vehicle. Manufacturers also often opt for adding a special structure to the bottom of the mats to reduce slippage. Another issue is the ease of cleaning the mats. The bristle used in the top layer should, on the one hand, take in moisture and dirt, while also being short enough to facilitate hassle-free maintenance. Naturally the structure of the car mats themselves is also important. They should be perfectly tailored to the specific model. This underscores the importance of the custom design phase.Depending on the specifics of a given project, both equipment providing high-frequency welding and, for example, eyelet machines will be required to prepare the appropriate fasteners. However, undoubtedly, it’s the former that plays a crucial role in achieving the desired outcome. Modern high-frequency welding machines, like Zemat Signa Duo , ensure the seamless joining of large parts with non-standard structures. This is especially important in the case of high-volume production. Another important consideration is personalization, a desirable feature in the automotive industry. For instance, logos or other markings can be introduced to enhance the car’s uniqueness and its accessories. Zemat machines offer more than just logo generation or markings – they enable specialized formatting of floor mats. This allows for the creation of customized foot pads or reinforcements precisely where the driver rests their heel. In this way, the mat is protected against potential damage from prolonged leg pressure.
WeatherTech has been manufacturing the highest quality vehicle floor mats since 1989. It’s a process that’s been perfected over countless hours, utilizing cutting edge technology and manufacturing methods to bring customers the highest quality floor mats that are laser measured for an absolute perfect fit. Currently, WeatherTech makes three different styles of vehicle floor mats for our customers. The WeatherTech FloorLiner, WeatherTech All-Weather Mat and WeatherTech Trim-to-Fit Floor Mat. Each of these products offers unparalleled levels of protection and are all geared towards the different seasons, scenarios and needs each of our customers may face.
Making each of these products requires a slightly different manufacturing process due to the materials each mat is made of. For example, Trim-to-Fit Floor Mats are not custom measured for individual makes and models, unlike the FloorLiner and All-Weather Mat. Those two products go through a rigorous round of product design and testing before being approved for manufacturing. Let’s take a quick look at how each of these products is made, right here in America!
Every WeatherTech FloorLiner and All-Weather Mat is custom measured for each vehicle application. This process begins with our product engineers that utilize the most sophisticated tools available to take a series of precise measurements in order to reverse engineer your vehicle’s floorwell. Once all the data has been collected these engineers use advanced, fully integrated Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) software platforms to create a virtual 3D model of the FloorLiner. Using free-form surface modeling, in which surfaces are defined, trimmed and merged, our product development engineers design and test the model’s feasibility before it ever moves forward with production.
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The 3D model created by our product development engineers is sent to the machinists at our tooling facility in Bolingbrook, IL. These highly trained and skilled American machinists use an American made CNC machine to create a metal mold out of the 3D modelling data provided by our product engineers. Once created, the mold is tested for accuracy. Pre-production samples of the FloorLiner or All-Weather Mat are created, and these samples are used to test the accuracy of the mold with its given vehicle application. The samples are measured, tested and if necessary the mold is slightly adjusted for accuracy. This may happen numerous times, as no floor mat product is approved for production unless the fit can only be described as perfect.
Once the molds have been approved for production, they are sent to our production facilities to begin mass production. WeatherTech FloorLiners, All-Weather Mats and Trim-to-Fit Floor Mats are all manufactured right in Bolingbrook, Illinois by skilled American workers, using all American materials. All the materials used to create our mats are not only sourced from other American facilities, but they’re also recyclable.
WeatherTech uses a patented High-Density Tri-Extruded (HDTE) material to create our FloorLiners. This material features a more rigid core which helps strengthen the product so it can stand up to any mess you throw at it. The HDTE material comes in large sheets that are then heated in a large industrial oven. Once these sheets are heated to the correct temperature they are pressed over the FloorLiner mold and then vacuum sealed down onto cooler metal’s surface. This process is called Thermoforming. It not only ensures a high quality final product, but also allows the FloorLiner to cool quickly; thus maintaining its shape and quality. Once the FloorLiner has been cooled it is removed from the mold, and if necessary some minor additional trimming may occur before it is ready for sale!
WeatherTech actually uses a slightly different material for its All-Weather Mat and Trim-to-Fit Floor Mat products. The material is an advanced rubber-like Thermoplastic Elastomer (TPE), and contains no latex, PVCs, cadmium or lead, and just like the FloorLiner material is still 100% recyclable. Mats made from this more malleable material must go through a different manufacturing process. WeatherTech All-Weather Mats and Trim-to-Fit Floor Mats are both created using injection molding. During injection molding, the different pieces of the metal mold are pressed together and the molten material is directly injected then quickly cooled. The mold is pulled apart and the resulting product is freed from the mold and ready to go!
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