KraussMaffei sets new standards in ColorForm technology

KraussMaffei is further developing its ColorForm technology for the in-mold coating of thermoplastic components. The company is presenting two innovations intended to improve flexibility and cost-effectiveness in the production of high-quality visible surfaces. The first is a newly developed multi-color mixing head that enables fully automatic color changes directly within the running production process. The second is a thin-layer polyurethane coating process developed together with long-standing development partner Siegfried Hofmann GmbH, which reduces the PU coating thickness to 0.1 millimeters. According to the companies, the developments extend the application potential of ColorForm by combining automated variant production with reduced material use while maintaining high surface quality.

Automatic color selection at the mixing head

KraussMaffei is presenting a new mixing head technology for flexible ColorForm series production of colored components. Several colors are available at the mixing head at the same time and can be selected automatically during production. This eliminates the need to replace color nozzles, change color modules or remove the mixing head.

"With the new mixing head, we enable fully automatic color changes directly during the ongoing production process. This provides maximum flexibility, shortens setup times, and makes the production of variants significantly more cost-effective," says René Dierkes, Head of Global Multi-Technology Projects at KraussMaffei.

Until now, a color change in ColorForm applications has required manual intervention at the mixing head. Color nozzles, color units or color modules had to be changed. Although this was already performed at high speed, it still required an interruption of the production process.

The new technology removes this step. All required colors remain permanently connected to the mixing head. The system automatically selects the desired color while the other materials continue to circulate in the loop. The color change takes place directly within the process, quickly, reliably and without mechanical retooling.

Thin-layer PU coating reduces material use

KraussMaffei and Siegfried Hofmann GmbH have also reached another milestone in reducing PU layer thickness. The two companies have been jointly advancing ColorForm technology since 2008. They have now succeeded in coating thermoplastic components directly in the injection mold with a polyurethane layer of only 0.1 millimeters.

ColorForm has previously been used to produce high-quality, scratch-resistant surfaces with layer thicknesses of up to 0.5 millimeters. The new development enables more resource-efficient production while maintaining the same high surface quality.

"By reducing the PU layer thickness from 0.5 to less than 0.1 millimeters, we are achieving a major technological leap. The resulting material savings of up to 80 percent significantly reduce the material costs for each individual component," says Andreas Bierbaumer, Technology Manager at KraussMaffei.

The reduction of the PU layer thickness to 0.1 millimeters was made possible by optimizing component fixation, the sealing system, the preform and the mixing head. The joint development by KraussMaffei and Hofmann demonstrates that ultra-thin PU layers can be produced directly in the injection mold with reliable processing and high quality.

"Together with KraussMaffei, we are using the development mold to demonstrate that layer thicknesses of this kind can be achieved reliably. The design and dimensions of the tool are based on current exterior automotive components such as trim panels or diffuser lenses. At the same time, we found that the surface quality can be improved and the scrap rate reduced," adds Stefan Hofmann, Managing Director and Owner of Siegfried Hofmann GmbH.

The new thin-layer process can be experienced live at the KraussMaffei TechCenter on a GX 650 with a spin-platen unit in combination with a mobile RimStar Compact 8/8. KraussMaffei and Hofmann will continue to jointly develop and market the technology to further expand the potential of in-mold coating for new applications and markets.

New thin-layer technology for a 0.1 mm PU layer thickness

Presentation at Fakuma 2026

Both innovations will be presented for the first time at Fakuma 2026. Visitors will be able to learn about the latest developments in ColorForm technology and how automated color changes and ultra-thin PU coatings can increase flexibility and cost-effectiveness in the production of high-quality plastic surfaces.

KraussMaffei will present the developments at Fakuma from October 12 to 16, 2026, in Hall 07, Booth 7303.