Attractive parts boast superior performance

Direct Skinning technology is a new production process that improves cost efficiency in the production of injection moulded parts in a single step. It has now been used for the first time with an aliphatic polyurethane material in the series production of vehicle interior parts. As part of a technology project devoted to the DirectSkinning process, fischer automotive systems GmbH and Bayer MaterialScience AG have been successful in jointly developing a decorative panel that is now manufactured in series production. The component seals off a kinematic drawer located on the dashboard of the BMW 5 Gran Turismo series directly above the central console. "Our joint project demonstrates that DirectSkinning is ready for series production and can be used to manufacture injection mouldings with high-quality, coloured decorative polyurethane surfaces for vehicle interiors," explains Dr. Michael Baumeister, Head of Production and Logistics at the Horb, Germany plant of fischer automotive systems. The approximately 1.4 millimetre thick covering for the panel is based on the polyurethane system Bayflex?LS (LS = Light Stable) from BaySystems. BaySystems?is the global umbrella brand for the polyurethane systems operations of Bayer MaterialScience. The system used here was specially developed for the DirectSkinning process. The panel is produced in five colours, including ivory white, light beige and gray. "Our polyurethane systems meet the growing demand for light colours in vehicle interiors as they deliver lasting UV resistance and colour fastness. They also give the surfaces a high level of scratch and abrasion resistance," says Gregor Murlowski, a polyurethanes expert at Bayer MaterialScience. The panel抯 thermoplastic substrate consists of the heat- and impact-resistant polycarbonate acrylonitrile-butadienestyrene (PC/ABS) blend Bayblend?T85, another material from the Leverkusen-based company. DirectSkinning technology combines injection moulding of thermoplastics with the reaction injection moulding (RIM) process for polyurethane processing. The coated component is produced directly on the injection-moulding machine in a single mould (multiple moulds are also possible) in a process that is comparable to multi-component injection moulding. After manufacturing of the thermoplastic substrate, the polyurethane system is injected into the closed mould via a polyurethane mixing head and the thermoplastic surface is thus coated. Parts produced in this way require very little secondary finishing. The thickness and colour of the polyurethane layer can be varied over a broad range. As the component is produced in a single mould, DirectSkinning does not require a separate coating system, in contrast to traditional methods. (the finished)Mens Nike Trainers