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Picture shows digital car cockpit

Smart panels for the automotive industry

Intelligent surfaces thanks to function integration

By combining the right materials with advanced injection moulding processes, intelligent surfaces can be created that not only meet high optical quality criteria, 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 the manufacture of smart panels

Solution in focus We supply solutions for complete production cells that are customised to the respective component concepts.

Strong partner network We have a global partner network of mould makers, material suppliers, film manufacturers, etc. at our disposal. This enables us to optimise our response to your requirements.

High process expertise Thanks to our extensive expertise in the field of injection moulding processes and process technology, we can design a customised production cell for you.

Smart panels in practice

Realised automotive panels for our customers

Picture shows automotive front panel made of plastic

Front Panel

Plastic combined with decorative foil and PUR-flooded surface

  • Design variety thanks to simple film change

  • Permeable for lidar and radar systems

  • Protection of the sensors

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

Rear end cover

Multi-component injection moulding combined with decorative film

  • Design variety thanks to simple film change

  • Transparent film areas

  • Lighting effects and touch function 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 foil

  • Self-healing surface

Design and manufacture of smart panels

Insights into the injection moulding production of automotive panels with intelligent surfaces

Kidney grille for the automobile

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

Kidney grille with integrated heating foil

Heating foil combined with the 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 roll-to-roll process

Film unwinder above the injection mould 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

Use of a robot in the production of intelligent surfaces

Automotive Front Panel

Automotive front panel with film integration 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 mould

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

I will be happy to advise you on the options for customising the 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 film designs

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

Plastic parts combined with PUR-flooded surface
The image shows the schematic system and layer structure of a Smart Panel with a PUR-flooded surface

Perfect high-gloss surfaces can be produced using the ENGEL clearmelt process. The plastic component is manufactured in a single process step 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 film is fed into the injection mould. Depending on the mould concept (sliding table or turning plate), the back-injected component is then coated with a PUR layer using the clearmelt process. The result: a visually appealing component with a scratch-resistant surface in just one process step.

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

Multi-component injection moulding 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

Substitution of the painting line, scratch-resistant and aesthetic surfaces, simple design change of the film layer and integration of functions can be realised in a single process step. Complex automotive panels can be created by combining the combimelt, foilmelt and clearmelt injection moulding processes and the corresponding tool designs. Optionally, the pre-moulded film can be fed into the process from the outside.

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

Films can not only be used to enhance the appearance of plastic components. The integration of functions using heating foils (in-mould electronics, IME), for example, offers another way of using plastic components effectively in the automotive industry. The combination of machine and mould concept with corresponding injection moulding processes turns visions into reality.

Multi-component injection moulding 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 upstream injection moulding process in the combimelt process enables the integration of assembly elements on the component itself, without the need for time-consuming reworking.

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

Large machine for smart panels

duo

Our two-platen injection moulding 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 dynamism.

  • Control directly via the injection moulding machine

  • Up to 270 kg load capacity

  • Simple integration into the injection moulding machine

Picture shows surface finishing of a plastic component from ENGEL

Injection moulding processes

clearmelt and foilmelt

Injection moulding 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 - personalised and intuitive driving experience
17 September 2024

Surfaces with integrated functions are becoming more present in our everyday lives. We ask Michael Fischer, Business Development Automotive, what impact smart user interfaces are having in the automotive industry and how much potential there is.

Read more

Christopher Stafford

Sales

Write to us

The ENGEL team will be happy to assist you with comprehensive know-how on the subject of injection moulding.

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