Case Study: Enhancing ADAS Camera Housing with PEM® TackSert® Fasteners
An automotive Tier 1 supplier had been developing an advanced multi-camera system designed to provide a seamless 360-degree view of a vehicle’s surroundings. Central to modern Advanced Driver Assistance Systems (ADAS), these camera systems enable critical safety features such as reversing assistance, blind spot monitoring, and automated parking.
The adoption of PEM® TackSert® fasteners significantly streamlined the assembly of ADAS camera modules, transforming the process into a faster, more reliable, and tamper-resistant operation. This boosted production efficiency, enhanced long-term performance, and increased packaging flexibility - key factors as OEMs and suppliers advance vehicle safety and automation.
Each compact camera module transmits real-time video to a central control unit, where the image data is processed to support driver alerts and autonomous responses. However, rising production volumes revealed inefficiencies in the assembly process - specifically, in securing the printed circuit board (PCB) within a precision-machined aluminum housing. The use of M2 screws increased labor time, risked damaging sensitive components, and limited design flexibility.
By replacing screws with TackSert® fasteners, the supplier overcame these challenges, aligning its production capabilities with the growing demands of next-generation ADAS solutions.
Challenges
- Reduce Assembly Time and Labor Cost: The screw-based process was slow and required manual torque application.
- Minimize Risk of PCB Damage: Over-tightening or tool slippage could damage sensitive electronic components.
- Work Within Tight Space Constraints: Limited internal space called for more efficient board layouts and fastening solutions.
- Ensure Tamper Resistance: The housing needed to remain permanently closed post-assembly to protect sensor alignment and data integrity.
- Improve Vibration Resistance: Camera systems mounted externally required secure, long-lasting fastening solutions that could withstand harsh conditions.
Results & Benefits
The implementation delivered immediate performance and process gains.
✅ 50% Reduction in Installation Time, eliminating the need for torque-controlled screwdrivers and reducing operator fatigue. The press-fit design minimized the risk of PCB damage, significantly improving assembly reliability.
✅ 30% Reduction in PCB Keep-Out Zones allowed for more compact layouts and efficient use of internal space.
✅ 60% Reduction in Head Height, enabling tighter packaging.
✅ 40% Increase in Retention Force over traditional screws, enhancing durability and resistance to vibration.
✅ Permanent Fixation ensures non-removability, reducing tampering risks preserving the alignment and performance of the camera throughout the vehicle’s service life.
Conclusion
The adoption of PEM® TackSert® fasteners transformed the camera housing assembly process into a faster, more reliable, and tamper-resistant operation. This change not only improved production efficiency but also enhanced the long-term performance and packaging flexibility of ADAS camera modules. As OEMs and suppliers continue to push the boundaries of safety and automation, advanced fastening solutions like TackSert® are proving essential to meet the evolving demands of modern vehicle design.
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