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Plastic Surface Finishing of Components
Injection Moulding for Sophisticated Designs and Functional Integration
When buying plastic products, aesthetics are becoming increasingly important. Functional properties are also gaining relevance. Our injection moulding processes ensure that manufacturers of visually appealing and multifunctional components achieve surface refinement and functionalisation of plastic parts. Thanks to the integration of several process steps in one cycle, you save costs and reduce the assembly workload.
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Change design quickly and easily
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Surfaces with diverse functionality
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Plastic surface finishing for greater robustness of parts
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Flooding for a haptic experience of the plastic surfaces
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Surface details thanks to heating and cooling in each cycle
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Visually appealing surfaces with recycled content
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More output through linking of production steps
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Production cell from a single source for increased part quality
The injection moulding process for film back-injection enables flexible component design. You can produce the same injection-moulded part in different colours, with different surface structures or with multi-coloured decorations – without changing moulds or materials. For example: you want to produce panels in blue and red and with different decors. With the classic injection moulding process, you would have to change the material and the type of printing. With film back-injection moulding, you only change the film inserted in the mould.
In addition to plastic surface finishing, film technology also enables the integration of various functions into the plastic parts. Some examples: The use of foils enables different visual impressions, especially under different lighting conditions. We integrate labels with the help of a carrier film. Preformed films allow complex component geometries. Film back-moulding enables an HMI interface through printed electronic control elements or heating of surfaces in winter to keep sensors functional.
When components have to be particular tough, flooding with a polyurethane coating is the optimal solution. In a production cell, the plastic substrate is first sprayed. In a second station, it is flooded with the reactive system. The thermosetting PUR protective layer gives components scratch resistance and impact strength. Self-healing effects allow scratches to disappear. The depth effect created by the coating gives a higher-quality impression.
Flooding creates haptically sophisticated surfaces that can have a variety of tactile properties. From rough to smooth, from hard to soft. The clearmelt injection moulding process can contribute to different haptic experiences depending on the requirements.
Variotherm processes are well suited to avoiding large-area or localised marking of weld lines. They are used for high-gloss effects on surfaces and can influence the filling behaviour for the smallest details. The processes are based on pressurised water or heat transfer oils and allow hot-cold switching of mould areas. They improve the detail accuracy of the components. Other variothermal processes are based on inductive heating solutions or the partial use of heating elements, among other things.
Decorative processes such as film back-injection or multi-component processes allow the use of recycled material. A front layer of the component can cover the structural component made of recycled material. In some cases, the use of recycled or bio-based materials is made visible in order to consciously focus on sustainability. This is achieved, for example, by overmoulding the functional surface with a layer of transparent material. The surface of the plastic part remains visually appealing.
Integrate multiple materials and surface functions in one injection moulding process. This minimises the time and costs for downstream assembly steps. Thanks to the multi-component injection moulding process, production takes place in one production cell. Sequential processes include core-back and sliding table technologies. They enable complex multi-component applications on machines with conventional clamping units. Maximum output is achieved with parallel processes using index, turntable or insert technology.
We design and manufacture your complete production cell, from the injection moulding machine to the robot and conveyor systems, right through to peripheral equipment. You get everything from a single source, including film or insert preparation and handling, also for clean room design. This is the straightforward way to set up production with the injection moulding process of film back-injection. You can rely on the highest part quality, stable injection moulding processes and high productivity when it comes to functionalisation and plastic surfaces.
The injection moulding process for film back-injection enables flexible component design. You can produce the same injection-moulded part in different colours, with different surface structures or with multi-coloured decorations – without changing moulds or materials. For example: you want to produce panels in blue and red and with different decors. With the classic injection moulding process, you would have to change the material and the type of printing. With film back-injection moulding, you only change the film inserted in the mould.
In addition to plastic surface finishing, film technology also enables the integration of various functions into the plastic parts. Some examples: The use of foils enables different visual impressions, especially under different lighting conditions. We integrate labels with the help of a carrier film. Preformed films allow complex component geometries. Film back-moulding enables an HMI interface through printed electronic control elements or heating of surfaces in winter to keep sensors functional.
When components have to be particular tough, flooding with a polyurethane coating is the optimal solution. In a production cell, the plastic substrate is first sprayed. In a second station, it is flooded with the reactive system. The thermosetting PUR protective layer gives components scratch resistance and impact strength. Self-healing effects allow scratches to disappear. The depth effect created by the coating gives a higher-quality impression.
Flooding creates haptically sophisticated surfaces that can have a variety of tactile properties. From rough to smooth, from hard to soft. The clearmelt injection moulding process can contribute to different haptic experiences depending on the requirements.
Variotherm processes are well suited to avoiding large-area or localised marking of weld lines. They are used for high-gloss effects on surfaces and can influence the filling behaviour for the smallest details. The processes are based on pressurised water or heat transfer oils and allow hot-cold switching of mould areas. They improve the detail accuracy of the components. Other variothermal processes are based on inductive heating solutions or the partial use of heating elements, among other things.
Decorative processes such as film back-injection or multi-component processes allow the use of recycled material. A front layer of the component can cover the structural component made of recycled material. In some cases, the use of recycled or bio-based materials is made visible in order to consciously focus on sustainability. This is achieved, for example, by overmoulding the functional surface with a layer of transparent material. The surface of the plastic part remains visually appealing.
Integrate multiple materials and surface functions in one injection moulding process. This minimises the time and costs for downstream assembly steps. Thanks to the multi-component injection moulding process, production takes place in one production cell. Sequential processes include core-back and sliding table technologies. They enable complex multi-component applications on machines with conventional clamping units. Maximum output is achieved with parallel processes using index, turntable or insert technology.
We design and manufacture your complete production cell, from the injection moulding machine to the robot and conveyor systems, right through to peripheral equipment. You get everything from a single source, including film or insert preparation and handling, also for clean room design. This is the straightforward way to set up production with the injection moulding process of film back-injection. You can rely on the highest part quality, stable injection moulding processes and high productivity when it comes to functionalisation and plastic surfaces.
 "Johannes Kilian | ENGEL")
Take advantage of our expertise, plant engineering and technologies for the surface finishing and functionalisation of your plastic parts. We will be happy to advise you on the design of your production cell.
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![Picture shows polyurethane flooding in the ENGEL clearmelt process]( "Polyurethane flooding in the clearmelt process | ENGEL")
ENGEL’s Innovations for Large Machines and Injection Moulding ProcessesSeptember 26, 2024At Fakuma 2024, ENGEL offers a comprehensive overview of the latest innovations in injection moulding and large-scale machinery at the "Large Machines & Technologies" Expert Corner.
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![Interview with Michael Fischer about Smart Panels]( "Smart panels and intelligent surfaces | ENGEL")
Blog![ENGEL Team]( "ENGEL Team")
ENGEL TeamSeptember 17, 2024Smart Panels - personalised and intuitive driving experienceSeptember 17, 2024Surfaces with integrated functions are becoming more present in our everyday lives. We ask Michael Fischer, Business Development Automotive, what impact smart user interfaces are having in the automotive industry and how much potential there is.
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systems solution
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automotive and mobility
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technology
9 minutes -
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![Picture shows employees of Faurecia and ENGEL]( "Practical example: surface finishing of plastic components | ENGEL")
Faurecia Produces Black Panels with Multi-Component Injection MouldingThe production of the centre console is demanding. It is a filigree frame structure made of plastic. Three materials are processed simultaneously in one step. The high-gloss lacquer requires an absolutely even substrate.
 "Polyurethane flooding in the clearmelt process | ENGEL")
 "Smart panels and intelligent surfaces | ENGEL")
 "Practical example: surface finishing of plastic components | ENGEL")
| Procedure | Product name | Industry | Applications | Process |
|---|---|---|---|---|
| Foil back-moulding | foilmelt | Automobile & mobility, technical injection moulding | Interior/exterior trims, fascias for white goods, smart panels | Create functional, haptic and decorative surfaces with foils |
| Multi-component injection moulding | combimelt | Automobile & mobility, technical injection moulding, medical technology, electronics, packaging | Interior/exterior trims, smart panels | Combine different types of plastic in one component |
| Variotherm technology | variomelt | Automobile & mobility, technical injection moulding, electronics | Fascias, white goods, TV frame | Achieve a high gloss surface through alternating mould tempering (hot-cold) |
| Flood | clearmelt | Automobile & mobility, technical injection moulding | Interior/exterior trims, fascias white goods, smart panels | Produce high-quality surfaces from polyurethane |
Foil back-injection is used for plastic surface finishing with a foil layer during the injection moulding process. The film layer can add value to your product, thanks to different surface designs or translucent parts, for instance. Additional electronic elements give surfaces special design accents with special effects or smart functions.
Design effects such as metallic, aluminium, chameleon effect or holograms on the surface of the component are possible.
You can implement different designs. Switching to a new design is quick and uncomplicated.
Direct injection moulding production of the surface design in a fully automated production cell. Without rework.
Fewer manufacturing and assembly steps by producing a fully functional component in a production cell. Result: savings in weight, time and costs.
Your plastic component is provided with a film layer through surface finishing and functionalisation
The component is visually upgraded
Preforming the film
Positioning of the insert by a robot
Hot substrate is injected by standard back- injection and fuses with the film
After cooling, the material and film are ejected in one piece
Foil is inserted into the tool
Foil is positioned in X and Y direction and clamped by a sealing frame
Hot substrate material is injected using the standard back-injection process and fuses with the PUR lacquer layer
After the material has cooled down, the film is ejected in one piece
Foil is inserted into the tool
Infrared preheating and vacuum preforming pull the film into the mould
Hot carrier material is injected in a standard back-injection process and fuses with the foil
When closing the tool, the film is cut by cutting edges
After cooling, the material and film are ejected in one piece
Preforming the film
Positioning of the insert by a robot
Hot substrate is injected by standard back- injection and fuses with the film
After cooling, the material and film are ejected in one piece
Foil is inserted into the tool
Foil is positioned in X and Y direction and clamped by a sealing frame
Hot substrate material is injected using the standard back-injection process and fuses with the PUR lacquer layer
After the material has cooled down, the film is ejected in one piece
Foil is inserted into the tool
Infrared preheating and vacuum preforming pull the film into the mould
Hot carrier material is injected in a standard back-injection process and fuses with the foil
When closing the tool, the film is cut by cutting edges
After cooling, the material and film are ejected in one piece
Produce innovative moulded parts from different materials in a single work step.
Procedural variants:
Multi-colour parts
Hard /soft composites
Thermoplastic/rubber Composites
Thermoplastic/LSR composites
Assembly injection moulding
Produce components with up to six injection units that can be controlled simultaneously or sequentially.
Machines for composite injection moulding with short cycle times.
The process enables colour variations and different haptic experiences.
The need for subsequent assembly and printing is eliminated. Different controls are produced in a single cycle.
Superior product features
Varied colour combinations
Additional component functions
Multi-component Injection Moulding in Practice
Experience combimelt technology at first hand. Integration of design and functionality on a tie-barless victory 330H injection moulding machine.
 "Multi-component Injection Moulding in Practice")
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With the variomelt injection moulding process, you heat and cool the mould in every cycle. The injection moulding process is suitable for the production of housings for modern consumer electronics. Preformed organic sheets can be perfectly overmoulded with PC-ABS.
Ideal for injection moulding modern consumer electronics, light guide panels, lenses, design parts and much more.
Robust housings or transparent parts with thin walls & even surfaces. Reduce visible weld lines and optimise the moulding of grains and geometries.
With other ENGEL injection moulding processes such as organomelt, optimelt, coinmelt and foilmelt.
Thanks to overspraying with translucent Piano Black paint.
Lamination of weld lines
Improved surface impression
Easier filling of thin-walled structures
With in-mould coating technology the surface refinement of your plastic parts succeeds during the injection moulding process. A PUR topcoat gives your product additional added value through scratch resistance, self-healing surfaces and a well-made appearance.
Scratch resistance, depth effect and a higher resistance to expansion even with thin coating thicknesses. PUR wall thicknesses from 0.4 mm to 10 mm are possible.
With other ENGEL injection moulding processes such as combimelt and foilmelt.
PUR-flooded carriers with integrated, capacitive functional film for optimum protection and convenient operation (e.g. car centre console).
Scratch resistant surfaces
Self-healing properties
Optical depth effect
IML stands for in-mould labelling. The surface refinement of the plastic component is achieved by using an inserted film that is back-moulded. If the film is already preformed, it is often referred to as FIM (film insert moulding). Other designations, which often differ according to the type of film, are IMF (in-mould foiling) or PFM (paintless film moulding). There are no standardised designations here.
IMD (in-mould decoration) is usually understood as a process in which colour is transferred from a carrier film to the component during back-moulding. The film runs from roll to roll. However, IMD is also sometimes used during film insertion. It therefore makes sense to discuss the exact process with ENGEL.
PUR stands for polyurethane. An additive reaction product of polyol and isocyanate, i.e. a thermoset. Polyurethane can be adapted to possess a wide variety of properties (hard-soft, self-healing, scratch-resistant).
PUR direct coating or IMC (in-mould coating) means that the thermoplastic carrier part is provided with the PUR coating directly on the injection moulding machine without intermediate demoulding. A combination of thermoplastic processes with a reactive process for the plastic surface finishing of parts is possible.
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