Headlights have long transcended mere illumination, evolving into technological carriers that deeply integrate design, safety, and sustainability. Today, a single beam of light suffices to identify a brand. All this converges in KraussMaffei's “FrontIQ Light,” showcased at K 2025.
 
FrontIQ lighting resembles a three-dimensional light sculpture infused with crystal elements, where design and function blend seamlessly. Swarovski Mobility crystal elements intertwine with an innovative holographic carbon fiber structure, creating a distinctive light signature and a stunning visual experience. Hidden heating wires can be integrated during manufacturing to prevent icing in radar areas under specific conditions. This technology is suitable for diverse modern mobility needs, from urban lighting and spotlights to adaptive lighting systems like dynamic cornering lights and daytime running lights.
 
Driving this transformation is KraussMaffei's ColorForm in-mold coating technology. Its value lies in a disruptive process: directly integrating polyurethane (PUR) surfaces during injection molding. This eliminates complex post-coating processes, replacing them with a one-step, in-line PUR layer applied with extreme precision down to 0.1 millimeters. The coating effectively resists UV radiation, stone chips, and chemical corrosion. This protective layer also enables diverse tactile effects and features self-healing capabilities for minor scratches.
 

Design Without Boundaries, Imagination Without Limits

This technology achieves a revolutionary leap in design capabilities. By integrating decorative films directly into the mold, it not only creates visually stunning effects with profound depth and unique textures but also provides instant surface protection—all without requiring any subsequent coating processes.

K 2023 witnessed the global debut of three-component in-mold decoration (3K IMD) technology. In collaboration with partner Leonhard Kurz, KraussMaffei showcased a 720-millimeter-long 3K demonstration part (headlight cover) on a turret-equipped GXW 650 machine, fully demonstrating the cutting-edge process from design to production for future automotive lighting.

This process transforms multiple prior steps into a single high-precision operation: after automatic preforming of flat film, it undergoes precise in-mold stretching into a three-dimensional shape and bonds with transparent and black polycarbonate, ultimately granting products unprecedented design freedom and unique character. The innovative gripper heating process ensures exceptionally uniform heating of the film, providing critical conditions for the in-mold transfer process and guaranteeing the highest quality, precise fit within the mold.

Precision. Cleanliness. Efficiency.

To achieve millimeter-level precision, KraussMaffei developed an automated solution: films undergo cleaning, precise positioning, and final forming. This continuous process guarantees flawless output while maintaining exceptional efficiency.

One-Stop Turnkey Solution

KraussMaffei delivers comprehensive end-to-end solutions. From automation and PUR to injection molding technology, all components originate from a single supplier and integrate seamlessly. This creates an entirely new process where design, functionality, and protective coatings fuse perfectly within the mold.

Article Link: Plastic Machinery Network  https://www.86pla.com/news/detail/74394.html