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In-Mold Coating - Slush Process |
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| OEM: | BMW | Model: | E63 M-Version |
| Model Year: | 2006 | Molder/Processor: | Intier Automotive Eybl Interiors GmbH |
| System Supplier: | Intier Automotive Eybl Interiors GmbH | Molder Contact: | Karl-Heinz Stelzl |
| System Contact: | Karl-Heinz Stelzl | Molder Phone: | 011 49 9421 708 100 |
| System Phone: | 011 49 9421 708 100 | Material Supplier: | Bayer Material Science |
| Toolmaker: | Galvanoform | Material Contact: | Sales Department |
| Toolmaker Contact: | Sales Department | Material Phone: | 011 49 214 300 |
| Toolmaker Phone: | 011 49 7821 947 0 | Generic Resin Type: | TPU |
| OEM Permission: | Yes | Grade: | 3790 AP |
| OEM Engineer: | Hans Schwager | Nominator: | Karl-Heinz Stelzl |
| OEM Title: | Director Plastics Development | Nominator's Company: | Intier Automotive Eybl Interiors GmbH |
| OEM Phone: | 011 49 89 382 46330 | Nominator's Address: | Stettiner Strasse 7 Straubing, Germany, D-94315 |
| Forming Process: | In Mold Coat (IMC) Powder Slush Molding Process | Nominator's Phone: | 011 49 9421 708 100 |
| First Time Process Used? | Yes | Nominator's Email: | karl-heinz.stelzl@intier.com |
| Weight Savings: | Same | Cost Savings: | 30% (Aromatic TPU is Resin is 60% cheaper than Aliphatic Molded-In-Color TPU; half of this savings is used to cover the cost of the IMC paint.) Roughly $1 per pound resin savings because we do not need to color compound the TPU (color is in IMC paint) and material losses due to milling different colored TPU to make the powder needed for the slush process. Less downtime because we do not need to change powder for different color. |
| Cost Avoidance: | N/A | ||
| Summary: This is the first in-mold-coating (IMC) - Slush process to produce instrument-panel skins. The process allows surface properties of a slush-molded skin to be decoupled from the substrate properties. By optimizing the surface and the substrate independently, conflicting customer requirements can be met. Cost savings of 30% were realized through the use of a lower cost aromatic TPU grade. | |||
| Most Innovative Feature: The IMC-Slush Process allows us to decouple the surface properties from the substrate properties of a slush molded skin. This decoupling allows us to optimize the surface and the substrate independently, enabling us to meet conflicting customer requirements. | |||
| Other Innovative Features: First IMC-Slush Molded
Instrument Panel Skin Application |
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