ColorForm Transcends Automotive Lighting Design Boundaries

Headlights have long surpassed their basic function of illumination to become technological carriers deeply integrating design, safety, and sustainability. Today, a single beam of light is enough to identify a brand. All this will be showcased by KraussMaffei at the K 2025 exhibition.“FrontIQ Light”The above content has been centrally presented.

FrontIQ lighting resembles a three-dimensional light sculpture incorporating crystal elements, where design and functionality are cleverly integrated. Swarovski Mobility crystal elements intertwine with innovative holographic carbon fiber structures to create a unique light signature and a stunning visual experience. Concealed heating wires can be integrated into the manufacturing process to keep radar areas free from ice in special conditions. This is suitable for adaptive lighting systems such as urban lighting, spotlights, dynamic curve assist lights, and daytime running lights, meeting the diverse needs of modern travel.

(This image is from Leonhard Kurz company)

One of the drivers of this transformation is KraussMaffei's ColorForm in-mold painting technology.Its value lies in the disruptive technology: integrating the polyurethane (PUR) surface directly within the injection molding process. This eliminates the need for complex subsequent coatings, replacing it with a one-step online completion of the PUR layer, with control precision reaching an extremely precise 0.1 millimeters, while effectively resisting ultraviolet rays, stone impacts, and chemical corrosion. The protective layer can also achieve a variety of tactile effects and has self-healing capabilities for minor scratches.

In terms of design dimensions, this technology achieves a revolutionary leap. By integrating the decorative film within the mold, it not only creates visually deep effects and exclusive textures but also provides immediate surface protection—all without the need for any subsequent coating processes.

The K Show witnessed the global debut of three sets of in-mold decoration (3K IMD) technology.KraussMaffei, in collaboration with its partner Leonhard Kurz, showcased a 3-component demonstration piece (headlight cover) measuring up to 720 millimeters on a GXW 650 device equipped with a turntable, fully demonstrating the cutting-edge process of future headlight design to molding.

This process integrates the previously multi-step procedures into a high-precision completion.After automatic preforming of the flat film, it is precisely stretched into a three-dimensional shape within the mold and perfectly combined with transparent and black polycarbonate, ultimately granting the product unprecedented design freedom and unique character. Among them, the innovative gripper heating process provides the crucial condition for the in-mold transfer process by subjecting the film to extremely uniform heating, thereby ensuring the highest quality precision fit within the mold.

To achieve millimeter-level precision fit,KraussMaffei has independently developed automation solutions.The film is first cleaned, then precisely positioned, and finally shaped. This continuous process ensures exceptionally high efficiency while guaranteeing a clean and flawless perfect output.

KraussMaffei offers complete solutions covering the entire process. From automation and PUR to injection molding technology, all aspects are provided by a single supplier and seamlessly integrated. This creates a new process where design, functionality, and protective coatings are perfectly integrated directly within the mold.