"By direct and fully automated linking of injection moulding, coating and final packaging with INSTANTCOAT® Plus we have reached the presently conceivable optimum in efficiency and product quality."
Dipl.-Ing. Michael Däbritz
Manager of VARIOPLAST®
- Material input
- Production scrap
- Personnel Costs
- Cycle Time
- Response time to problems
- Storage time of parts before coating
Critical aspects are improvement of part quality, process repeatability and flexibility:
- Regular coating layer thickness
- Improved surface appearance
- Improved coating adhesion (dirt-free parts)
- Part defects directly recognizable during process
- Shorter reaction time in case of malfunctions
- Process parameters repeatable and coordinated.
Mountingframe
2K-Injection Moulding + CO2 pre-cleaning + coating + dry + coating + dry
INSTANTCOAT®: 75% reduction of the ecological grey footprint
Source:
Download
Mountingframe result sheet LCA assessment SKZ - Das Kunststoff-Zentrum |
High-tech injection molding
2K-Injection Moulding + Sheet Metal Overmolding + Insert Overmolding + US-Welding + Pad Printing + polishing + Drill
„The INLINE-metallization process INSTANTCHROME® by means of PVD, developed by VARIOPLAST®, is a perfect fit for our strategy of INHOUSE-process chains and has replaced galvanic chrome plating in our company.“
Dipl.-Ing. Michael Däbritz
Manager of VARIOPLAST®
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The process chain of INSTANTCHROME®
1. Injection Moulding
2. Priming, UV-coating/drying
3. Chrome plating (PVD-Coating)
4. Topcoat (decorative protective coating) with solvent based and solvent free coatings, UV coating
5. Automated packaging of the coated products -
Advantages of INSTANTCHROME® versus galvanization process
● Fully automated process from injection moulding to ready-coated and packaged product
● Repeatable due to exactly adjustable parameters for coating and chrome plating
● Qualitative advantages due to constant process conditions
● Significantly lower scrap rate
● Direct part assessment during process
● No Hot Touch Effect
● Energy conservation
● Environmental compatibility (no hazardous waste)
● Cost savings -
Applications of INSTANTCHROME®
Decorative and functional coatings (matt and shiny)
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Significant Advantages compared to galvanically chrome-plated parts
● Selective coating for fiber optics/reflector
● Various coating materials and polymers applicable
● Even snap-on hinges, clip closures, film hinges possible
● Ultrasonic welding, day & night design lasering feasible -
Hochschule Karlsruhe – Bachelor Thesis at Varioplast
Coating process of the PVC-Magnetron-Sputter process with optimization of the chrome coating by application of optimal design of experiments on the physical functionality of Magnetron Sputtering - optimal design and application of experiments (DoE) - Characteristics and Behaviour of Chrome during sputtering
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Fulfilled Objectives
● no visible cracking
● best adherence of chrome on plastics
● optimization of UV-protective coating in accordance with quality standards of automobile manufacturers
● coating with paint (Primer/Topcoat)
Black Panel Technology
2K-Injection Moulding + Variothermie + Pad Printing + PVD-Coating + coating + US-Welding + Laser cutting