Premiere: Fully Automated Production Process of the Decoject Surface Foil at the K 2016

Premiere: Fully Automated Production Process of the Decoject Surface Foil at the K 2016

At the world’s most important trade fair for the plastic and rubber industry, the K 2016 in Düsseldorf, ContiTech‘s surface specialist Benecke-Kaliko, together with its strong industrial partners, will present its innovative Decoject foil solution in a fully automated component production process for the first time. Interested parties can experience the advantages of the new technology live from October 19 to 26 in hall 15 at booth C58 of the mechanical engineering manufacturer Engel.

Decoject: cost-efficient, highly scratch-resistant surface with an exclusive feel and appearance

Decoject, the cost-efficient alternative solution to injection molding, allows the appearance and function of car interiors to be upgraded. The foil cannot fail to impress with its enhanced scratch resistance, and also offers an exclusive appearance and a comfortable feel. Using paints, printed decor, or effect coatings opens up a wide range of design options. The gloss level and feel can be adjusted as desired, decor can be changed easily and quickly, and the color can be changed without process waste. With Decoject, Benecke-Kaliko offers customers three further advantages: a foil solution with high surface quality, ultra-high flexibility for small batch sizes, and low unit costs.

Lowering of unit costs by means of new production process

At the K 2016, the fully automated Decoject processing will be presented on a system for the first time. The machine produces sample parts modeled on large-surface door panels. To highlight the wide range of the new technology, the components have different surface structures, including a sophisticated carbon grain and incorporated decorative elements.

It takes only 60 seconds to produce a ready-to-install component

As soon as the tool opens, the Decoject thin foil is drawn in. It is heated up by the infrared lamp placed in the gripper, and pre-shaped directly in the injection-molding tool by means of a vacuum. Immediately after this, the foil is injection-molded on the back and punched out. The robot then removes the component and transfers it to the integrated laser station for fine cutting. A ready-to-install component leaves the production cell every 60 seconds. If the design has to be changed, it only takes a few minutes to replace the foil roll. As a result, the batch size is no longer reflected in the unit costs. This level of automation makes a decisive contribution to the procedure’s high cost-effectiveness and flexibility.

Visitors can experience the Decoject technology three times a day: from 10 a.m. to 12 p.m., 1 p.m. to 3 p.m., and 4 p.m. to 6 p.m. in hall 15, at booth C58 (Engel).

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