KraussMaffei
At K 2025, KraussMaffei, together with its partners LEONHARD KURZ and Rühl, will be showing what the front light of tomorrow will look like: The “FrontIQ Light” combines design, function and protection in a single highly integrated manufacturing process. At its heart is ColorForm technology, in which thermoplastic components are given a precise polyurethane surface directly in the injection mold.
While conventional headlights require a cost-intensive hard coating, the “FrontIQ Light” uses an inline-applied PUR layer to protect against UV radiation, stone chipping and chemical influences. The coating layer can be precisely adjusted in the tenth of a millimeter range and enables variable haptic effects as well as a self-healing effect for fine scratches. “With our ColorForm technology, KraussMaffei is revolutionizing the front light: from design freedom with printed films to precise 3D forming – all in an intelligently networked complete solution,” explains Dr. Frank Szimmat, Managing Director of KraussMaffei Technologies.
A world first is the tool-integrated film thermoforming: The film is three-dimensionally formed directly in the tool. This creates maximum design freedom – from sophisticated depth effects to individual surface patterns. Precision is ensured by an automation solution that cleans the films in advance, positions them precisely and shapes them to an exact fit. Thanks to the integrated automation, the gripper has a heating process that makes film thermoforming possible in the first place. This innovation creates extremely precise and even heating of the film – the basis for the highest quality and perfect fit in the tool. Despite the complexity, the process runs smoothly as all steps are provided from a single source.
Design freedom through film integration
The special feature: The combination of several thermoplastics, decorative film and PUR surface opens up almost unlimited design possibilities. Brilliant depth effects, individual patterns and durable protection are created directly in the tool – without subsequent coating processes. The surface is designed using films printed using thin-film technology, which are back-injected with transparent and black polycarbonate in the tool using the sheet-to-sheet process. “Automotive design today is more expressive and emotional than ever before. With concepts such as the “FrontIQ Light”, we are taking design to the next level – seamless, sustainable and full of new possibilities. Light becomes a language and surfaces become a brand experience,” says Luitpold Haarländer, Head of Sales Management Automotive at LEONHARD KURZ.
Complete turnkey solutions from a single source
KraussMaffei supplies ColorForm technology as an end-to-end solution, from automation and PUR technology to injection molding technology. The result is a highly integrated process in which design, function and protective layer are created directly in the mold, without additional post-processing.
At K 2025, visitors will be able to experience the technology live on a GXW 650 with turntable. A 3K demonstrator in the design of a 720 millimeter long headlight will be on display at the LEONHARD KURZ stand in Hall 5 / A19.
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