3K IMD Process

Production-ready technology with maximum efficiency

Is it possible to produce, decorate, and apply a protective coating to automotive components made of three different plastics and measuring up to two meters in a single process step? KURZ's innovative 3K IMD process makes it possible - with an optimized cycle time of less than two minutes. The energy- and cost-efficient technology can also be integrated into existing production lines and can contribute to a significant improvement in the CO₂ balance compared to conventional processes. This allows the production of highly integrated components that combine design, light, and function - such as innovative headlights and other components for the design of the vehicle front, which are perfectly tailored to the requirements of e-mobility and autonomous driving.

Form, design, and PUR protective coating in a single process step

With the 3K IMD process, we are introducing a groundbreaking innovation: In this highly efficient process, all steps – injection molding, deep drawing, and decoration – are carried out directly in one system. Three different plastic components are joined in a single process. Thanks to the VARIOFORM sheet-to-sheet technology with an innovative clamping frame system, combined in a 2K indexing machine with a PUR Colorform system, there is no need for upstream thermoforming – in line with lean, energy-efficient production.

First, a thermoplastic sheet is picked up by robotic arms and inserted into the mold. It is then shaped into the desired form using heat and vacuum pressure.
Transparent PC is applied to the formed sheet using injection molding technology. This layer enables the optical functionality later on.
Once this step is complete, the middle mold halves are rotated 180°. Thanks to this unique feature, which is made possible by the next generation scalable turning plate technology from KURZ subsidiary SCHÖFER, the process is ideal for manufacturing large components from a 3K material mix.
In the next step, a stabilizing frame made of opaque ABS/PC is injection molded, followed by another rotation of the inner mold halves.
Finally, the component is flooded with polyurethane (PUR), which provides it with a protective layer – for added durability, scratch resistance, and longevity. Bio-based PUR can be used on request.