In the beginning there was an idea...

In 1988 European automotive parts manufacturer Marling Industries, Leek, GB, who produce safety belts, planned to begin the production of airbags. They had the brilliant idea to produce a double layer fabric using jacquard weaving techniques. The concept to create a woven seam by interlacing both fabric layers was patented.

The resulting successful trials led to a joint venture with the Swedish company Electrolux, known for electronic automotive components, to provide an economical basis and market promotion for the OPW airbag. This was the birth of Airbags International Ltd.

Even before the completion of this joint venture, the OPW team was in close contact with DORNIER. For reasons of secrecy the work was carried out at H. H. Calmon, a weaver in a suburb of the city of Bradford (this location was also conveniently close to the facilities of DORNIER’s U.K. agent). After trials in Lindau, two weaving machines of dobby and jacquard specifications were delivered to Calmon. This was the beginning of an intensive collaboration between supplier and customer. Contrary to any other fabric, the hollow fabric woven using jacquard structures needed to be of so far unknown precision regarding yarn densities, even distribution of ends right up to the selvedges, high and uniform tenacity and absolutely faultless. Following many discussions with European car manufacturers, after auditing the production facilities of both machinery supplier and airbag manufacturer. Ford Europe decided, in May 1992, to fit driver-airbags as standard in their 1993/94 Mondeo-models. A passenger airbag was offered as an option with the intention to include it as serial equipment later.

Then followed a period of rapid growth as AIL was selected to supply many other car manufacturers. The budget plan for the period 1992 – 1995 included the installation of 30 weaving machines. This number had to be progressively amended so that today there are 80 machines operating. The take-over of the automotive products division of Electrolux by Autoliv made it possible for AIL to establish their facilities in an existing factory site in Congleton, housing 30 rapier weaving machines, bag finishing line and an R & D centre.

By 1995 the production capacity when weaving up to 3 bags side by side was approx. 4.5 million bags per year. This was not enough. New developments and continuous strong demands led to a decision to erect a completely new factory in Congleton. At the same time further evaluation and development by AIL and DORNIER confirmed the capability of the air-jet weaving machine with jacquard to produce OPW airbags. This was the signal for the investment in 50 airjet weaving machines for the new factory, delivered between 1995 and 1998.

With 830 employees and 80 weaving machines AIL is today producing some 15 million bags per year. The Autoliv group operates gas generator and module plants in Germany, Spain, Sweden and the U.K. where bags are also assembled and, where required, built into steering wheels. From these plants complete assemblies are delivered to the various European car manufacturing plants.

An end to the expansion cannot yet be seen. In 1997 Autoliv merged with the American car safety component maker Morton and were thus able to enter the vast American market. Now even this market benefits from AILīs OPW airbag, however with a high degree of innovation and adaptation. Because of the spacious limousines and the fact that there is no legal requirement to use safety belts in most States, there are further special requirements. AIL is accepting these challenges by developing new OPW airbag designs.