BMW X3: where function meets design

The illuminated decorative centre-console part combines a matte chrome film with a PUR surface, produced in a fully automated 3K process with in-mould labelling.

The emission-free, paint-free and plating-free process is ideal for sites with strict environmental regulations. The key challenge is the reliable integration of multiple materials and the sensitive decorative film into a highly automated series production process.

• High precision and stable 3D visual effects
• Eco-optimised — no painting or galvanic plating

TPE-O airbag cover: lightweight without compromise

The TPE-O mono-material delivers 45% lower CO₂ emissions with premium surface quality and full recyclability — a strong step towards a circular economy.

Achieving a flawless surface despite the foaming process is mastered through precise process control on the ENGEL system.

• Precise, repeatable surface quality
• Mono-material enables easier recycling

E-mobility: next-gen thermoplastic battery housing

An advanced thermoplastic system for high-voltage applications achieves about 43% lower lifecycle CO₂ while meeting stringent safety and mechanical requirements.

• Full support — from concept to series production
• Lower weight and faster processing for higher efficiency

Organomelt: convertible-top cover (Mercedes-Benz CLE)

Heating and forming of organic sheets combined with subsequent injection moulding yields a fully recyclable solution that is about 15% lighter than the metal version.

• High process integration with reduced waste
• Enables series production of lightweight structural parts