Direct Coating

Direct coating is an in-mold coating technology in which the production of a plastic component and its surface finishing take place in an integrated process. The process combines classic injection molding with coating directly in the tool and is primarily used in automotive engineering and in industrial applications for high-quality plastic surfaces.

In contrast to conventional painting or coating processes, which require several separate process steps, with direct coating the coating is applied immediately after injection molding. The molded part is transferred to a second cavity where it is coated with a low-viscosity two-component polyurethane that cures directly in the mold. External coating lines, drying ovens and additional handling steps are no longer required.

A key advantage of direct coating is the high level of process integration. Shorter cycle times, lower energy consumption and reduced emissions improve the cost-effectiveness and sustainability of production. At the same time, the process enables a high degree of design freedom, as decorative and functional surfaces can be realized with consistent quality, such as high-gloss, matt or textured coatings with haptic effects.

In terms of technology, direct coating places high demands on materials and process control. Reliable adhesion between the plastic substrate and the coating is crucial, which is why specially matched thermoplastics and polyurethane systems are used. With the growing demand for integrated and resource-efficient manufacturing processes, direct coating is becoming increasingly important for the industrial series production of high-quality plastic components.