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Picture shows digital car cockpit

Smart panels for the automotive industry

Smart surfaces thanks to function integration

By combining the right materials with advanced injection molding processes, it’s possible to create smart surfaces that do not only meet high optical quality standards, but also enable a wide range of functional integration. Produce ready-to-install smart panels in just one process step and avoid unnecessary rework and high production costs.

Benefit from our expertise in producing smart panels

Solution in focus We provide solutions for complete production cells, customized to suit specific component concepts.

Strong partner network We have a global network of partners including toolmakers, material suppliers, film manufacturers, and so on. This allows us to respond optimally to your requirements.

High process expertise Thanks to our extensive knowledge of injection molding processes and process technology, we design customized production cells for you.

Smart panels in action

Automotive panels realized by our customers

Picture shows automotive front panel made of plastic

Front panel

Plastic combined with decorative foil and PUR-flooded surface

  • Design versatility thanks to easy film change

  • Permeable for lidar and radar systems

  • Protection of sensors

Picture shows a smart panel manufactured by injection molding in the form of a rear end cover

Rear-end cover

Multi-component injection molding combined with decorative film

  • Design versatility thanks to easy film change

  • Transparent film areas

  • Lighting effects and touch functionality possible

Picture shows functional automotive kidney made of plastic

Exterior design

Plastic with functional film and PUR-flooded surface

  • Permeable for lidar and radar systems

  • Integrated heating film

  • Self-healing surface

Design and manufacturing of smart panels

Insights into injection molding production of automotive panels with smart surfaces

Kidney grille for a car

Heating film combined with the clearmelt process for the production of automotive panels

Kidney grille with integrated heating film

Heating film combined with clearmelt process for the production of automotive panels

Rear-end cover

Rear end cover manufactured using the combimelt process with design film

Film unwinding in the roll-to-roll process

Film unwinder above the injection mold for the foilmelt process in the roll-to-roll process

Decorative foils on complex geometry

Complex 3D geometries are produced using the foilmelt process with different foil designs

Production of a smart panel

Utilization of a robot in the production of smart surfaces

Automotive front panel

Automotive front panel with integrated film and PUR top layer - still permeable for liDAR and RADAR systems

Production of a smart panel

Production of a smart panel with a sliding table mold

Picture shows Business Development Manager at ENGEL Austria
Do you want to produce smart panels for the automotive industry?

I am happy to advise you on the possibilities of the individual layer structure of your component.
Together we will find the right solution.

Options for system and layer construction of and for smart panels
Plastic parts combined with decorative foils
Image shows the schematic system and layer structure of a smart panel with decorative foil designs

The optical refinement of plastic surfaces can be easily achieved with the ENGEL foilmelt process. Whether using the roll-to-roll or in-mold decoration process, the result is a component with an aesthetic surface manufactured in just one process step. The foil or design can be changed easily.

Plastic parts combined with PUR-flooded surface
The picture shows the schematic system and layer structure of a smart panel with a PUR-flooded surface

Perfect high-gloss surfaces can be achieved with the ENGEL clearmelt process. In one process step, the plastic component is manufactured and then coated with a scratch-resistant, self-healing PUR layer. This saves you time-consuming and expensive painting and coating lines.

Plastic parts combined with decorative foils and PUR-flooded surface
Image shows the schematic system and layer structure of a smart panel with film and PUR-flooded surface

In the ENGEL foilmelt process, a foil is fed into the injection mold. Depending on the mold concept (sliding table or turning plate), the back-injected component is then coated with a PUR layer in the clearmelt process. The result: a visually appealing component with a scratch-resistant surface in just one process step.

Multi-component injection molding combined with decorative foils
The image shows the schematic system and layer structure of a smart panel using the combimelt process with decorative film designs

The integration of lighting elements into plastic components and automotive panels enables new design approaches in both automotive exteriors and interiors. The decorative film is back-injected with transparent plastic using the ENGEL foilmelt process. In the combimelt process, a second, dark thermoplastic layer is produced. This allows geometries to be molded that are required for the subsequent assembly of the component.

Multi-component injection molding combined with decorative foils and PUR-flooded surface
The picture shows the schematic system and layer structure of a smart panel using the combimelt, foilmelt and clearmelt processes

Substituting the painting line, achieving scratch-resistant and aesthetic surfaces, facilitating easy design changes of the film layer, and integrating functions can be implemented in a single process step. By combining the injection molding processes combimelt, foilmelt and clearmelt with the corresponding tool designs, complex automotive panels are realized. Optionally, the pre-formed film can be fed into the process from the outside.

Plastic parts with decorative, functional foils and PUR-flooded surface
The picture shows the schematic system and layer structure of a smart panel using the foilmelt and clearmelt processes with the integration of heating foils

With the help of films, not only can the appearance of plastic components be enhanced, but also the integration of functions through, for example, heating films (In-Mold-Electronics, IME), offers another opportunity to effectively utilize plastic components in the automotive industry. The combination of machine and tool concepts with corresponding injection molding processes make visions a reality.

Multi-component injection molding with functional foils and PUR-flooded surface
The picture shows the schematic system and layer structure of a smart panel using the combimelt and clearmelt processes with the integration of heating foils

To protect the functional film, a scratch-resistant and self-healing PUR layer is applied using the clearmelt process. The preceding injection molding process in the combimelt process allows for the integration of assembly elements directly onto the component itself, without the need for time-consuming rework.

Solutions for the production of smart panels
Picture shows large ENGEL machine for the production of smart panels

Large machine for smart panels

duo

Our two-platen injection molding machine for the production of decorative or functional elements in the automotive industry.

  • Large tool area

  • Wide range of options

  • Integration of various processes

Picture shows green articulated robot

Articulated robots

easix

Our easix masters complex movements and high part weights with precision and dynamics.

  • Control directly via the injection molding machine

  • Up to 270 kg load capacity

  • Easy integration into the injection molding machine

Picture shows surface finishing of a plastic component from ENGEL

Injection molding processes

clearmelt and foilmelt

Injection molding processes that enable the integration of a wide range of functions and designs.

  • Simple design change

  • Scratch-resistant and intelligent surfaces

  • One-shot process

What else you might be interested in
Blog
Smart panels - personalized and intuitive driving experience
September 17, 2024

Surfaces with integrated functions are becoming more present in our daily lives. We asked Michael Fischer, Business Development Automotive, about the impact of smart control surfaces in the automotive industry and the potential they hold.

Read more

Markus Lettau

Sales

+1 (717) 767 2016

Write us

The ENGEL team is happy to support you with extensive knowledge in the field of injection molding.

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