Covestro is strengthening its global support for Direct Coating in-mold coating technology. The process combines injection molding and polyurethane coating in an integrated two-component process and is particularly aimed at applications in the automotive industry.
Integrated process instead of multi-stage coating
In conventional manufacturing processes, plastic components are often coated in several successive steps, which involves additional energy consumption, longer throughput times, and limited design freedom. In the direct coating process, the injection-molded part is transferred to a second cavity and coated with a low-viscosity 2K polyurethane coating that cures directly in the mold. Separate painting or coating systems are not required.
The integrated process can shorten cycle times and reduce process complexity. In addition, different surface structures as well as haptic and visual effects can be created directly in the mold.
Materials and application support
Covestro provides both suitable polycarbonate substrates and specially developed polyurethane raw materials for direct coating applications. These include low-viscosity, fast-curing polyisocyanates and polyols that are tailored to the combined injection molding and coating process.
Covestro also supports users with advice on tool design, process parameters, and scaling. Components can be tested and manufacturing conditions validated in technical centers. A comparison tool also allows cost and emission figures to be compared with conventional coating processes.
Use in series applications
According to the company, Covestro materials have been used by a German automotive manufacturer for direct coating components in interior and exterior applications since 2021. The technology is suitable for near-series applications and is designed to enable flexible transfer to different component geometries.