Automotive coatings innovation with Direct Coating – The In-Mold Coating technology

Covestro is strengthening its global support for Direct Coating – The In-Mold Coating technology, a single, integrated two-shot in-mold process that combines injection molding with a polyurethane (PU) coating. Direct Coating reduces costs and energy, streamlines production, and enables the manufacture of higher-quality, more design-flexible coated plastic components for automotive applications.

This is important because the conventional vehicle part coating process typically involves multiple steps, each of which adds cost, uses energy, and limits design freedom. Direct Coating from Covestro transfers the molded part to a second cavity and applies a low viscosity 2K PU that cures in the mold. This integrated process requires no conventional coating- or painting lines, accelerates cycle times, streamlines operations, and enables more flexible, scalable production of a range of coating designs, including those featuring haptics and visual effects.

“With a broad network of partners across the entire value chain, we are well-positioned to support the global rollout of Direct Coating,” said Benjamin Herzberg, Technology Expert IMC at Covestro. “We have over two decades of proven experience in the Direct Coating process, with a strong focus on joint projects across the automotive industry. Our application and scale-up expertise is anchored across technical centers worldwide and backed by a strong IP portfolio. Our latest customer support enhancement is a tool that compares cost and CO₂ emissions with the conventional manufacturing process.”

End-to-end solutions and support

Covestro also offers tailored polycarbonate substrates such as Makrolon^® IMC2477. This solution delivers excellent adhesion to polyurethane coatings while maintaining good optical properties in both transparent and colored opaque finishes. Additionally, Covestro has designed dedicated polyurethane coating raw materials for Direct Coating applications. These materials include fast-curing, low-viscosity polyisocyanates and polyols suitable for these applications.

“Customers can accelerate their time-to-market by benefiting from guidance on mold design and process optimization, as well as using our facilities to trial designs and validate parts and production conditions,” added Thomas Baeker, Marketing Manager for Industrial and Automotive Coatings at Covestro.

Since 2021, a leading German automotive manufacturer has used Covestro products for Direct Coating components in both exterior and interior vehicle applications.