The manufacture of plastic components using polyurethane (PUR) flooding – known as the Engel Clearmelt process – continues to evolve, and the applications are becoming increasingly complex. The Austrian injection moulding machine manufacturer Engel recently showcased a new milestone: a rear light cover manufactured without a costly hard coating, using a combination of Foilmelt and Clearmelt technologies.
Innovative products and processes such as these require expert support and comprehensive project management. To meet this need, the company established the new Clearmelt Competence Centre (CCC), where a dedicated team of specialists will provide full-service support for all polyurethane processing projects.
Engel’s Clearmelt process is an innovative injection moulding technology that enables the optimised production of scratch-resistant, high-quality plastic surfaces – particularly for visible parts with demanding aesthetic requirements. The process supports high-volume production of decorative components with significantly reduced cycle times, making it highly productive and cost-efficient. From a technological standpoint, the company uses a multi-component technology to mould a thermoplastic substrate, which is then overflooded with PUR.
Engel has more than two decades of experience with polyurethane flooding, and has continuously refined and developed the process over time. At the international plastics trade fair K in October, the company presented a new application concept for this technology, marking another milestone in the production of automotive components.
The demonstration combined the manufacturing of a decorative and functional rear light cover in a single injection moulding cycle. The automotive rear light module (Figure 1), measuring 600 x 240 mm, was produced in Dรผsseldorf on a Duo 700 two-platen injection moulding machine. To achieve greater design and variant flexibility, the module was manufactured using an intelligent combination of the Clearmelt process and Engel’s Foilmelt injection moulding technology. After moulding, a functional film with integrated OLEDs was bonded to the part’s interior to add electronic features. Thanks to the scratch-resistant surface finish created by the Clearmelt process, no costly hard coating is required as an additional downstream process step.
Cover photo: The space-saving Viper linear robot ensures precise handling and seamless synchronisation, supporting shorter cycle times and maximum layout efficiency (source: Engel)
source : https://magazine.jeccomposites.com
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