Bayer Material Science has an IVECO prototype dashboard made with their new DirectSkinning technology. Here, they overmold a Bayblend® PC-ABS with a Bayflex® polyurethene coating, practically a combination of injection molding and coating. The new technique renders a cost effective short processing chain with replicable foamed surface structure that is scratch and UV resistant.

KraussMaffei’s ColorForm process is a world first. It can completely replace conventional painting, including pre- and post-paint work processes. ColorForm integrates injection molding and a reaction molding process. For the first time, processors can produce multicomponent parts with premium high-gloss surfaces in a fully automated single-stage process. At the KraussMaffei booth they show the production of a design study case made of ABS. In the first step the base material is injection molded. After the center plate of the mold is rotated, the cavity closes again and the second, soft component (TPU) is injected to form the handle as well as the connection part on the bottom. Now, the specially developed lacquer component Polyurea is overmolded in a very thin layer over a flow length of 40 cm. The two parts of the case are alike, so a robot assembles them in the last step outside the mold. The whole case is ready within a minute. The KraussMaffei project was taken to its successful completion with their partners Hofmann Innovation Group GmbH and Panadur GmbH.

Bayer Materials Science brings us an integrated polycarbonate rear hatch. The backlite is part of the polycarbonate outer skin and, as such, is directly integrated into the tailgate. Unlike conventional glazing units, it no longer has to be glued in, thus simplifying assembly. A rear spoiler and two styling lines – one of them directly in the area of the backlite – have been molded directly on to the prototype part. Tail lamps, indicators, brake lights, license plate lights and the raised brake light are located behind the polycarbonate outer skin. The relevant fixings and guides can be directly integrated using the two-component back-injection method.

A tailgate manufactured exclusively of polycarbonate would not be stiff enough to meet all the load specifications. That is why Bayer integrated reinforcing ribs of polycarbonate, which are molded on to the inside of the tailgate. Simple strips of sheet metal are inserted in the grooves between the ribs and bonded with an elastic adhesive. The elasticity of the adhesive evens out the differences in heat expansion between the metal and the amorphous plastic.

Siemens and Arburg joined forces to make a polyamide 6 substrate for electronic applications. What is so special about this part, is its thickness: it is 0.2mm thick with a cycle time of only 2.5 seconds. The material is injected into the ultra-thin cavity in only 0.07 seconds. They are able to achieve these high speeds, while maintaining precision and control, thanks to their linear motor with high acceleration capacity.