With laser structuring and subsequent electroless metallization, three-dimensional plastic parts are made into three-dimensional circuit carriers. An innovative feature is the addition of an inexpensive rapid process for manufacturing prototypes to the process chain. 

3-D Printing for MIDs 

3D-MID-Baugruppen

Oberflächentechnik

Laserbearbeitungen

Laserstrukturieren

Copper Conductors from the Bath 

Pharmaceutical crimp caps generally consist of a thin aluminum sheet and a plastic component, and are used to seal medical vials, for example for vaccines. Through a combined deep-drawing and backmolding process with previous inline laser treatment of the thin aluminum sheet, the process can be significantly shortened. The media-proof joining together of the two materials is carried out through a mechanically interlocking connection.

A crimp cap for injection vials is manufactured in a two-step process.

16:9

Combined Deep-Drawing and Backmolding Process with Mechanically Interlocking Joint

Hybridtechnik

Kunststoffverarbeitung: Verfahren

Spritzgießen

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Aluminiumlegierungen

Metall Werkstoffe

NE-Metalle

Tiefziehen

Verfahren für die spanlose Fertigung

Spritzgieß-Sonderverfahren

Simulation Stanzen / Umformen

Software

Simulation

Hybrid-Spritzgießen (Metall / Kunststoff)

Medizintechnik

Medizinprodukte

Process Chain for the Production of Hybrid Medical Products

Lightweight construction, small batches, and progressive integration of electronic functions: general industrial trends are spilling over into the injection molding industry. Recent years have seen the development of remarkable solutions for meeting all kinds of requirements. Machine manufacturers have not been idle though: precision-regulated processes form the basis for many applications, and now it seems that the self-optimizing injection molding machine is no longer a fantasy. 

Visible and Invisible Innovations Continue to Confer Benefits on the Industry.  And on Mankind, too? 

Steuern, Regeln

Additive Fertigung

Spritzgießmaschinen

Mehrkomponenten-Spritzgießen

Metallpulver-Spritzgießen

Folientechnik (IMD, IML, FIM, u.a.)

Schaumspritzgießen

Temperiertechnik

Nobel Prize for Injection Molding 

The imminent paradigm shift in mobility makes it essential that the German automotive industry prepares itself to undergo a transformation, both now and in the future, the like of which has not been seen before. Resource-efficient lightweight system engineering in a multi-material design is a key differentiating feature here. In this connection, novel materials, highly automated, digitized manufacturing processes as well as functional integration for intelligent component structures and vehicle systems will form the basis for creating springboard innovations that will dominate the competition. 

Innovative Injection Molding Technologies for Hybrid Lightweight Applications 

Elektromobilität

Thermoplaste

Verbundwerkstoffe / Werkstoffverbunde

Magnesium

Faserverarbeitung

Warmformen / Thermoformen

Inserttechnik

Beschichten von Metallen, allgemein

Verbindungstechnik, hybride

Plastic and Metal − an Inseparable Team 

In the Federal German Excellence Cluster "Merge", new processes for hydroforming-injection molding for processing thermoplastic fiber composites are being researched. With gas as a forming and supporting medium, fiber-reinforced plastic tubes have been processed for the first time. In specific applications, researchers succeeded in reducing the part weight and process costs, and increasing productivity. 

A Merger of Hydroforming and Injection Molding Technologies Is Driving Lightweight Design 

Kunststoff-Profile

Towards the Functionalized FRP Tube 

In a joint project, seven companies developed a combination of technologies for manufacturing electronically functionalized high-quality surfaces, e. g., for applications in and on the car. Demo parts were shown in public for the first time at Fakuma 2018.  

Combination of Technologies for Manufacturing Electronically Functionalized Plastic Parts 

HMI, Bedienelemente, Displays

Polyurethan

Lackieren

Premium Surfaces by the  One-Shot Process 

Four project partners showcased their companies at Fakuma last October by means of an ingenious give-away. Two of the companies involved ¿ Horst Keller Werkzeugbau and Hasco ¿ have already enjoyed a dependable working relationship for almost 50 years. They implemented the project, based on an idea by injection molding machine manufacturer, Dr. Boy, in a very short time, together with a third partner from their network. 

Four Companies Team up for the Joint "Check Card" Project 

Normalien und Heißkanaltechnik

Multifunctional Trade-Fair Give-Away 

The filling of injection molds with plastic melt depends, among other things, on the surface quality of the mold cavity. An application-oriented structuring of the cavity surface increases the length of the flow path of the melt by up to 18 %, depending on the plastic material. This opens up the possibility of achieving longer flow paths with existing injection molding technology. 

Structured Surfaces in Injection Molds Allow for Longer Flow Paths 

Rheologie

Everything Keeps Flowing 

Transparent functional and design elements often consist of glass and plastic materials. But there may be problems in bonding them. High-strength hybrid connections are made possible with a two-step process, in which a laser first creates micro- and nanoscale structures in the glass, into which the plastic melt can subsequently penetrate.

Laser structuring of a glass sample by means of CO2 laser radiation: the microstructures are introduced into a glass substrate with a thickness of 3 mm at spacings of 1 mm. This is performed by means of a scanner system, which guides the laser beam over the glass substrate in multiple passes at high speed. When the laser beam impinges on it, the material is vaporized; the ablated particles can be seen as a yellow jet of flame 

Innovative Glass-Plastic Hybrid Combinations through Precise Laser Structuring

Laserschweißen

Verbindungstechnik Verfahren

Thermisches Fügeverfahren

Lasertechnik

Uniting Glass and Plastic

Together with 14 other partners from industry and research, the Fraunhofer Institutes for Production and Laser Technology – IPT and ILT in Aachen, Germany – are developing industrial processes for the production of parts made from metals and fiber composite plastics.

Laser structuring: high-intensity laser beams evaporate local metal, thereby creating micro structures with undercuts. Fiber composite plastics can then bond well to pre-treated surfaces by mechanical clawing

Laser Based Production Methods Make Hybrid Parts Practicable

UD-Tapes

Kunststoff Werkstoffe

Verstärkungsstoffe

Schnüre, Bänder, Tapes

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Locally Reinforced Auto Body Parts

The joining of dissimilar materials is a special challenge for joining technology. Thermal direct joining together with suitable surface treatments enables stable joints between very dissimilar materials combinations, thus offering an alternative to classic procedures for joining hybrid parts.

This electronics housing composed of an aluminum die casting with PA6 covers is a potential application case for thermal direct joining

Thermal Direct Joining of Plastic-Metal Combinations for Industrial Applications

Aluminium

Polypropylen

Alternatives to Gluing and  Mechanical Joining

With integrated process chain, high strength and media tight plastic/metal hybrid components can be produced from laser-structured metal semifinished products.

Three stages of the manufacturing process of a headlamp reflector. From left to right: die cast reflector insert, back-molded hybrid reflector, reflector after PVD coating.

Magnesiumlegierungen

Beschichten (CVD, PVD)

Chemisches Bearbeiten (Auftragen)

Leichtbau

Lichttechnik

Polycarbonat

Form-Fitted Hybrid  Lightweight Construction

The implementation of innovative lightweight construction concepts in new, more efficient products requires fast and reliable joining and cutting processes which can process a plethora of different lightweight materials. Laser radiation stands out as a tool for processing materials mainly because it does not involve any contact and energy input is wear-free. 

Efficient Joining and Cutting Processes for All Kinds of Lightweight Materials in the Micro and Macro Range 

Werkzeuge für Leichtbauwerkstoffe

Laser Technology for Lightweight  Industrial Applications 

Three-dimensional molded interconnect devices combine electronic and mechanical functions. Plastics additives are necessary for activating surfaces using lasers, and they enable selective metallization. Relevant parameters of various additive/polymer combinations have been identified in a current study. 

Selective Metallization of Plastic Components with Laser Direct Structuring 

Additive

Entering the Third Dimension with Light-Colored LDS Additives 

Due to their high-gloss surfaces, ABS and SAN copolymers are classically used in claddings, dashboards and panels. A new development cooperation has now investigated a wide range of these materials for different surface designs using lasers.

Fig. 1. The 16 different laser-engraved surface structures tested  on the styrene copolymers 

Laser-Grained Styrene Surfaces for Automotive Interiors and Exteriors Parts

Oberflächenbeschichtung

Holz

Polystyrol

Styrol-Copolymerisate

Oberflächenveredelung

Dienstleistungen

Lohnfertigung

Markieren und Oberflächenbearbeitung

Matt is the New Shining

Elegant Design Ideas for the Automotive Interior

With a symbiosis of 3D texture, coating and lighting, Reichle Technologiezentrum, Mankiewicz and Lightworks are creating a day-night design with new possibilities.

With a symbiosis of 3D texture, coating and lighting, Reichle Technologiezentrum, Mankiewicz and Lightworks are creating a day-night design with new possibilities. The element of surprise comes from the fact that the effect of transilluminated surfaces is not visible in daylight, and only appears when the lighting is switched on.

Megatrends such as electromobility and autonomous driving are changing not only the automotive industry but also the design of all products. In the automotive interior, the focus is on the surfaces – and the user experience they provide. At least that is the way it is seen by Marco Reichle, CEO of the Reichle Technologiezentrum GmbH in Bissingen/Teck, Germany.

Design and Optics Alone Are Not Enough to Provide the Desired User Experience

“Creating attractive interior spaces and ambient lighting solely through design and optics is no longer sufficient to meet modern expectations,” says Reichle. “The principal aim of interior spaces now is rather to achieve an interplay of functionality and experience.” This goal was implemented by the laser expert in a concrete practical example. A joint project was conducted to investigate the partial transillumination of 3D-textured surfaces.

For this, Reichle brought two partners on board: the team from Bissingen has been working closely with Mankiewicz GmbH & Co. KG and Lightworks GmbH for years. Together, they developed a new concept for ambient lighting. The clever part is an element of surprise for the vehicle occupants. It comes from the fact that the impact of transilluminated surfaces and crystals is not visible in daylight, and only appears when the lighting is switched on. This effect is achieved with a combination of surface design, lasered 3D texture and light and coating systems.

The Texturing of the Surfaces Is Lasered into the Mold

In this project, a crucial role was played by the product design. In a first step, the designers shaped the surface of the part such that an aesthetic surface is created in daylight while at the same time patterns and effects that are normally invisible become visible at night. The developed surface was machined into the mold inserts on a 5-axis laser system from the manufacturer GF Machining Solutions.

The challenge here was that no CAD data records of the shrunk plastic part, including texture, existed. Reichle Technologiezentrum therefore uses algorithms developed by its research and development department to introduce textures accurately, even into shrunken parts, with a tolerance of only one to two hundredths of a millimeter. Subsequently the surface was provided with a specially developed multilayer coating system, which permits partial transillumination and creates a light concept that determines the type of illumination.

Personalizations of the Logo through to Antibacterial Design

As regards the personalizability of the day-night design, the technology allows maximum design freedom. From the 3D texture implemented with laser technology, through the light, to coating, which can be given “anti-fingerprint” or even antibacterial properties, entirely new design possibilities are opened for the user. The holistic design concept involves completely closed surfaces, which meet all the requirements of the automotive standard. Decoration, texture, coating and light meld seamlessly together without additional contour guides, and offer a tactile and optical experience. Even logos, lettering and graphics can be engraved in this way. The basic plastic part forms the basis of the design, meaning that no additional investment is required. By realizing the transillumination on the part surface itself, undesirable parallax effects can be additionally avoided. Compared to conventional film backmolding, which cannot be implemented on textured surfaces with partial lighting, the day-night design concentrates on 3D-textured surfaces, thus allowing a high degree of precision and an accuracy of fit of a few micrometers.

Thanks to the design freedom, it is available as an optional extra or else personalized to a quantity of one in large series. The possible applications are in particular decorative trim, complete door panels, center consoles or, in the near future, exterior applications, such as front headlamps, tail lights, radiator grilles, or even outer skin parts – but also applications for electrical equipment, aircraft, furniture and bath and kitchen fittings. Typical applications such as different textures in different driving modes, illuminated serial numbers for special series or a combination with touch functions are only some of the conceivable possibilities.

The Reichle Technologiezentrum, together with Lightworks GmbH, develops the entire lighting technology. Starting with the lighting simulation, development of the entire lighting system, via design of the low-profile light guide with the necessary outcoupling optics, through to realization in the injection mold, making exclusive use of high precision femto laser technology, which is essential for the necessary precision.

In the development project, Mankiewicz developed and implemented the special coating systems, so that a transillumination solution that is invisible in the day design could be realized by means of completely closed surfaces. Likewise, the special laser primer is a new development that is convincing for its layer thickness of only a few micrometers.

For the special ambient lighting, each individual technology also poses special challenges:

<ul><li>Moldmaking: depending on the texture and texture depth, an offset must be maintained in the mold, so that an absolute dimensional accuracy can be ensured and the mold parting surfaces fit precisely. The required offset concept can be very complex, in particular for fade-out effects.</li><li> Laser Texturing: the accessibility in the mold for the laser beam must be ensured. During the laser texturing itself in the mold, there are no major challenges, they lie rather in the prior design development.</li><li> Injection Molding: stable dimensional stability throughout the series process. The wall thicknesses of the plastic parts consisting of transparent PC or PMMA are 2 to 3 mm.</li><li>Coating: the very thin layer thicknesses of the special coating systems.</li></ul>

Is There a Trend for the Future of the Automotive Interior?

Marco Reichle is satisfied with the results of the project. What moved him to start this development project? Reichle: “Vehicles are unimaginable today without ambient lighting, however for many years they have been realized in very similar ways via contour light guides. In the future, we see a symbiosis of light and décor, which is why we decided to integrate ambient lighting directly into decorative trim or general plastic parts, so that we can provide an element of surprise in the night design. Our effort was therefore in particular to realize the entire topic on 3D-textured surfaces, since no technical, process-stable solution has been available until now. Film backmolding with partial, accurately fitting areas onto a texture or graining is not feasible with present technology.

A series-capable solution for overmolding crystals is currently being developed in order to be able to present an economic manufacturing process.

Reichle Technologiezentrum GmbH  

https://www.reichle.de

Ausgabenartikel

Specially coated Swarowski crystals reflect the light as computed by the designer in advance.

Decorative strips in the vehicle with partial transillumination in day-night design.

Seeing the future of the interior in a symbiosis of light and decor: Marco Reichle, director of the Reichle Technologiezentrum.

The left-hand picture shows a mold insert, the pictures to the right of it show two different lighting versions that appear when the lighting is switched on.

Reichle - Hauptartikel

Sophia Weiss works in marketing at Reichle Technologiezentrum.

Read the German version of the article in our magazine Kunststoffe or at <a href="https://www.kunststoffe.de/a/fachartikel/ambientebeleuchtung-mit-wow-effekt-2673738" target="_blank">www.kunststoffe.de</a>