The Customer:

Any customers manufacturing parts with demanding criteria for surface quality, such as automotive suppliers making cockpit components

The Task:

Manufacture ready-to-install door trim panels to an OEM design

The Problem:

Products have to meet rigorous quality criteria (haptics, softtouch) and the manufacturing process must be cost-competitive

The Solution:

SkinForm application in a complex manufacturing cell which combines injection moulding, reaction moulding and automation. The challenge for automation is ensuring that the release agent is accurately sprayed and inserting clips while also integrating different types of robot.

The Outcome:

The side panels are made on a KM 2300-12000/4300 MX WEN SpinForm machine. The rigid component is first injection moulded in one daylight of the spin-platen machine. The spin platen then swivels the mould half containing the part into the second daylight where the flexible component (PU) is injected. The part is demolded by a console-type KR 150 L 110 robot installed on a console next to the machine, which removes the sprue and transfers the parts first to a laser cutting cell and then to a clip assembly station. The floor-mounted robot stacks the finished parts in a transport carriage. While the part is being demolded, the shelf-type IR 2000 - 1200 S-XL industrial robot sprays release agent into the mould for the start of the next cycle. The SpinForm manufacturing cell guarantees a stable process. The outcome is a technology highlight. The complete system was supplied by KraussMaffei.