How to Increase Throughput and Reduce Variation in Airbag Clamp Installation
January 13.2026 | Essential Applications
Meeting throughput goals while controlling variation is one of the toughest challenges in automotive safety system production. For engineers responsible for airbag modules, selecting the best clamp for airbag module installation plays a direct role in avoiding rejected parts, slower production rates and compliance risk.
These outcomes are costly, especially with increasing pressure to meet IATF 16949 requirements and supply chain documentation standards. The Dual-Lokt® Intelligent Clamping System was designed to address these exact problems.
Let’s look at how manufacturers can improve clamp installation speed, control variation and support compliance by moving away from traditional clamp solutions.
Clamp Variation Leads to Downtime and Quality Risks
In high-volume airbag module production, time spent correcting installation issues is time lost. Many common clamp systems lack force verification, and some create uneven stress along the clamp edge. If the clamp is installed too loosely or too tightly, it can either slip or damage the airbag fabric. Either scenario creates rework and wasted material.
Even more critical is the risk of quality escapes. A clamp failure in the field is a manufacturing problem and a public safety issue.
Traditional pinch ear clamps were never built to meet these production and safety expectations. For today’s engineers, something more reliable is needed.
The Dual-Lokt System Solves for Speed, Accuracy and Consistency
BAND-IT developed the Dual-Lokt system to meet the performance needs of modern airbag systems. From its low-profile design to its retained force performance, every detail was engineered to support better production outcomes.
Why Dual-Lokt?
- It delivers retained force up to 2.5 times higher than traditional pinch ear clamps.
- The installed clamp lip does not leave sharp edges, reducing risk to nearby components.
- The clamp conforms over multiple shapes, reducing the need for part-specific SKUs.
- It supports accurate installation with tool-controlled closing speeds.
- Tooling systems provide digital verification for each install, supporting audit requirements.
Higher Throughput Without Compromising Quality
Reducing installation variation helps your team maintain higher throughput. With Dual-Lokt, the clamp and tool system work together to limit operator error and support repeatable, in-spec installations across shifts and job sites.
Traditional solutions leave accuracy to the installer. BAND-IT’s tooling supports a different approach – one where installation parameters are controlled and logged. That’s a game-changer for high-volume safety system production.
Instead of relying on manual checks, manufacturers can build traceability into their process with tools that verify the job was done right.
Installation Tools That Support Compliance and Reduce Fatigue
BAND-IT tools are designed with ergonomics in mind. In applications like airbag modules, where tight workspaces and repetitive motion are common, tool weight and configuration can impact operator performance.
One key advantage of Dual-Lokt over pinch ear clamps is its ability to achieve greater diameter reduction. This makes the clamp easier to stage and position over tight-fitting airbag assemblies, which reduces strain on installers and helps prevent repetitive motion injuries. By improving how the clamp fits and functions in constrained spaces, the system supports operator safety and long-term comfort on the line.
The Dual-Lokt system was designed for production environments where precision and repeatability must be maintained over thousands of cycles. Built-in tool diagnostics and adjustable parameters give engineers control over the process.
Tool data can be used to show that each clamp meets specifications, an advantage when supporting IATF 16949 requirements or supplier audits.
Reducing SKU Count and Simplifying Logistics
Inventory complexity creates cost. Because Dual-Lokt clamps are capable of handling a wider range of diameters, many customers are able to reduce the number of SKUs they carry.
Fewer clamp part numbers mean simpler procurement and fewer mistakes during assembly. This is especially valuable for sourcing teams balancing cost control with supply assurance.
A Trusted Solution Backed by Decades of Application Expertise
BAND-IT is an established name in the automotive space. For more than 85 years, BAND-IT has supplied engineered fastening solutions for applications where reliability is not optional. From airbag modules to exhaust systems and steering rack clamps, our team understands what’s at stake when failure is not acceptable.
Dual-Lokt continues that tradition. It reflects what’s possible when engineering, manufacturing and installation tooling come together in a single solution.
See if Dual-Lokt Is a Fit for Your Program
If your team is facing inconsistent installs or production delays related to clamp systems, it may be time to assess your current setup.
Contact BAND-IT to schedule a review. We’ll help evaluate your current clamp performance and explore whether the Dual-Lokt system could reduce variation and support your throughput goals.