Covestro: Automotive coating with in-mold coating Direct Coating

Covestro is strengthening its global support for Direct Coating in-mold coating technology - an integrated two-component injection molding process that combines injection molding with a PU (polyurethane) coating. Direct Coating reduces costs and energy consumption, optimizes manufacturing and enables the production of higher quality coated plastic components for automotive applications with greater design flexibility. Given that the traditional coating process for automotive parts typically involves multiple steps, each of which adds cost, consumes energy and limits design freedom, this is a major advantage. With Direct Coating from Covestro, the molded part is transferred to a second cavity and coated with a low-viscosity 2K PU that cures in the mold. This integrated process does not require conventional coating or painting lines, speeds up cycle times, streamlines operations and enables more flexible, scalable production of different coating designs, including those with haptic and visual effects.

Direct coating in automotive coating

"With a broad network of partners along the entire value chain, we are well positioned to support the global introduction of direct coating," says Benjamin Herzberg, Technology Expert IMC at Covestro. "We have more than 20 years of proven experience in the direct coating process - with a focus on joint projects in the automotive industry. In our technical centers around the world, we offer application and scaling expertise, supported by a strong IP portfolio. Our latest achievement in customer support is a tool that compares costs and CO₂ emissions with the conventional manufacturing process." In addition, Covestro offers customized polycarbonate substrates such as Makrolon IMC2477. This solution offers excellent adhesion to polyurethane coatings and retains its good optical properties on both transparent and colored opaque surfaces. Covestro has developed specialty polyurethane coating raw materials for direct coating applications. These materials include fast-curing, low-viscosity polyisocyanates and polyols. "Our customers can shorten their time to market with our advice on mold design and process optimization and use our facilities to test designs and validate parts and manufacturing conditions," adds Thomas Baeker, Marketing Manager for Industrial and Automotive Coatings at Covestro. A leading German car manufacturer has been using Covestro products for direct coating components in the exterior and interior of vehicles since 2021.