Krauss Maffei technology chosen for BMW’s 5 Gran Turismo Series

Fischer Automotive Systems GmbH, a processors of plastic automotive systems, has adopted a new technology, called DirectSkinning, from Krauss Maffei of Munich Germany, a world leader in plastics machinery.

 DirectSkinning involves multi-component injection moulding, in a single mould, with a PUR coating that protects the thermoplastic substrate.  The ‘skin’ – PUR coating – is applied using reaction injection moulding (RIM) equipment directly to an injection moulding part in the same mould in which the thermoplastic parts are formed. After moulding, the PUR system is injected into the closed mould via a mixing head, coating the substrate.

The first commercial DirectSkinning part being manufactured by Fischer, is a decorative panel that seals off the kinematic drawer located on the dashboard, directly above the central console, of the BMW’s 5 Gran Turismo series. The panel is manufactured in 5 different colours and has a 1.4mm thick PUR covering and is made from a polycarbonate/arcylonitrile-butadiene-styrene (PC/ABS) blend, Bayblend T85, which is supplied by Bayer MaterialScience.

The thickness and colour of the PUR coating layer can be controlled and the investment and floor space required is less than if two machines - one each for injection and RIM - were installed.  Significantly the logistics and simplified as parts are ready to ship as they leave the processing cell and no paint lines are required.

“Our joint project demonstrates that DirectSkinning is ready for series production and can be used to manufacture injection mouldings with high-quality, coloured decorative polyurethane surfaces for vehicle interiors” said Michael Baumeister, head of production and logistics at Fishcer’s facility in Horb, Germany