Smart Molding International 2-2023

33 www.smart-molding.com molding technology "Plastics let all of these waves through, which is why they have already replaced aluminium and steel in automotive front and rear ends," said Fischer. "Autonomous driving is a massive opportunity for plastic injection moulding. More efficient than any other method of plastics processing, injection moulding helps to combine sensor systems and electronic features with a visually appealing design." Among other processes, ENGEL developed its clearmelt technology for this purpose; clearmelt is a two- component process that combines in-mould decoration (IMD) with p o l y u r e t h a n e f l o o d - c o a t i n g . "Flood-coating with polyurethane in the mould allows for a perfectly repeatable, smooth surface with a uniform wall thickness," says Fischer: "This predestines the technology for integrating optical sensors." BMW i n Landshut uses th i s technological basis to produce the "kidney" panels for the BMW iX electric vehicle in a cleanroom setup. Once the radiator grille, this characteristic design feature of all BMW models has taken on a new role following electrification of the drivetrains. The kidney-shaped panels protect a series of sensors for assisted and, in the future, autonomous driving. To make sure that the sensors also work reliably in the winter, BMW back- injects a heatable f un c t i ona l f i lm w i t h p o l y c a r b o n a t e , which is then flood-coated with polyurethane. Following several applications for the vehicle interior, this is the first time that BMW is using a combination of film back- injection and flood-coating in the series production of functional parts on the exterior, where they are exposed to particularly high stress. The sensitive electronics are well protected under the scratch-resistant polyurethane surface. The high gloss level and depth effect, which even a thin coating of polyurethane achieves, convey a very elegant impression. ENGEL is the system supplier for this demanding project. The production cell integrates an ENGEL duo combi M injection moulding machine with a horizontal rotary table, two large articulated robots for handling the films and moulded parts, a film cleaning system, an inline quality- control station and peripheral units including the polyurethane feed. ENGEL is collaborating with development partners in the field of combined back-injection and PUR flood-coating, including Leonhard Kurz Stiftung, Schöfer and Votteler Lackfabrik. In the scope of a project study, the partner companies were able to demonstrate that flood- coating with polyurethane, which is equivalent to in-mould painting in terms of the process, accounts for only 20 percent of the total energy consumed in the production process. This means that the integrated process offers significantly improved energy- efficiency compared with painting the parts outside of the injection moulding process. Efficient lightweight composites with thermoplastics Lightweight plays a central role in achieving climate protection targets. At its own interdisciplinary technology centre for lightweight composites at the St. Valentin production plant in Austria, ENGEL has been developing innovative composite solutions in cooperation with partner companies for more than ten years. The primary development goal is integrated and automated processes for cost-efficient high-volume production. One focus of the development work is on the use of thermoplastic fibre composite materials. “The reasons for this are the highly efficient processes for processing thermoplastics on the one hand, and greater sustainability on the other ”, said Füreder. An approach which consistently relies on thermoplastic material paves the way for recycling the parts later on. I n t h e E NG E L o r g a n ome l t p r o c e s s , t he rmop l a s t i c f i b r e composite prepregs – for example, thermoplastic sheets and UD-Tapes – are shaped and functionalised in a single integrated step. To achieve this functionalisation, reinforcing ribs or assembly elements are moulded immediately in the same mould after thermoforming using a thermoplastic from the same matrix material group as the thermoplastic sheet. The first high-volume production application of this technology went live in 2018 at Valeo Front End Modules in Smyrna, Tennessee, USA. Starting with thermoplastic sheets, Valeo Front End Modules manufactures front end carriers with integrated air ducts for a German brand name OEM at its plant. The systems solution supplied by ENGEL for automated high volume production consists of an ENGEL duo 1700 injection moulding machine, In the ENGEL organomelt process, Valeo Front End Modules manufactures front end carriers with integrated air ducts for a German brand name OEM in Smyrna, Tennessee