Pioneering hot runner solutions driving the future of automotive trends

Color in the automotive industry goes beyond aesthetics; it can shape consumer behavior, strengthen brand identity, and even influence vehicle purchasing decisions. As plastic part design continues to evolve and sustainability becomes an increasing priority, the challenges in injection molding grow. In response, In-mold color technology offers a cost-effective and high-quality solution, providing a brilliant and durable finish without the added costs or environmental impact of traditional painting methods.

This advanced manufacturing technique incorporates pre-colored plastic resins directly into the injection molding process. Oerlikon HRSflow brings comprehensive expertise in managing In-mold color technology across various materials such as PP, TPO ABS and PC-ABS. The optimized thermal profile of the channels together with an optimized nozzle and tip geometry ensure a smooth, direct injection on the part, producing finished components in the desired color and appearance in just one step. With this approach, secondary processes like painting or plating are eliminated, speeding up production and making parts easier to recycle. Additionally, scrap is significantly reduced, lowering both the overall cost of production and the environmental impact.

This technology is versatile and can be applied across a wide range of automotive applications, such as exterior parts (i.e. bumper, wheel arch, spoiler…) as well as internal one (IP, central console, door panel).

An innovative look for automotive front panels
At Fakuma 2024, Oerlikon HRSflow unveiled the newly designed Mercedes EQB Star Panel. Featuring a high-gloss black surface decorated with a star pattern, this fresh design aligns perfectly with the future needs of the automotive industry. The molded part, weighing 920 g and measuring 2.5 mm in thickness, is crafted from PC/ABS BayblendT65 xf and produced using Oerlikon HRSflow's sequential hot runner system, consisting of 1 drop Ga and 6 drops Ha series. This optimal hot runner solution guarantees the component's impeccable appearance, meeting the rigorous standards of the vehicle's advanced features. Furthermore, the hot runner system includes specialized gate inserts that minimize maintenance and enhance efficiency, boosting overall productivity.

The project was conceived in cooperation with Gerhardi.

New Horizons for the Lighting Industry
At the booth, Oerlikon HRSflow showcased several advanced applications, including the Head Lightbar for the automotive sector, crafted from crystal-clear polycarbonate (PC) and produced using the innovative FLEXflow HRS hot runner system technology. This application, provided courtesy of Automotive Lighting, demonstrates the precision and innovation driving the industry forward.

FLEXflow HRS technology, powered by servo motors, enables perfectly synchronized pin management, delivering exceptional flow front accuracy in sequential injections. This advanced solution minimizes sudden pressure drops, ensuring more uniform cavity filling and reducing stress on the plastic components.

This flexibility is not limited to the filling phase alone; during the holding phase, needle profiles (including speed and stroke) can be individually adjusted to meet specific product requirements, offering unmatched versatility.

Family tools are also gaining momentum within Automotive Lighting's product line. Designed to lower initial investments and optimize production setups, this approach requires thorough engineering studies and precise considerations to ensure that final results meet expectations. Oerlikon HRSflow brings the most advanced technology and deep expertise to its customers, providing solutions not only for opaque surfaces but also for transparent components. Additionally, the company offers specialized hot runner solutions to meet the latest trends in car lighting, from decorative to functional layers.

Aesthetic effects, particularly in back-lit elements such as car logos, headlights, and taillights, are becoming increasingly popular, especially in interior automotive products. Oerlikon HRSflow is at the forefront of this growing trend, delivering innovative solutions that meet the evolving needs of the industry.