INPRO Innovationsgesellschaft mbH Berlin

Painted vehicle surfaces are a key quality criterion. It might influence the consumer's buying decision to a great extent, but it remains a major cost factor. Therefore, approaches are being sought, which can reduce production costs in some areas.

In combination with composite construction procedures, the question of cost-effective coating of components that are not necessarily required to pass through the manufacturer's complete paintshop needs to be addressed. For components made of plastic, foil techniques offer an innovative alternative to conventional vehicle paintwork.

In contrast to existing plastic painting, these technologies offer a so-called line coater with foil, which is decorated in the vehicle's colours. After thermoforming with this foil and back-foaming / back-spraying with a fibreglass-reinforced polymer matrix, the finished component will fit the painted chassis.

INPRO has followed foil technology since 2002 and has been developed a prototype process chain to apply this technology. At the end of 2004, the general suitability of foil technology was demonstrated by means of the pilot component "Touareg panel". This facilitated the presentation of the potential of this technology for production painting of plastic components.

The study of various scenarios for foil coating on the basis of a specific component or as a complete covering have shown that film technology is of interest from an economic point of view. Foil technique is an innovative technology with significant application and process potential.

 In 2008, this was employed in series production on the VW Passat CC.