Based on the same basic substrate, the surface of a raw part can be finished in a variety of ways, e.g. chrome-plated, painted, foiled. To make this possible, appropriate coordination is required in the project phase and adjustments made in the tool design phase to prepare the component requirements for this surface variety. An additional effort with great benefits, because with careful advance planning, the range of surfaces can be considerably expanded with a simple tool investment.
The Solingen-based automotive supplier BIA makes use of this principle to offer its customers the widest possible range of surface finishes. For example, electroplatable blanks, which are usually injection-moulded from ABS or a PC/ABS blend, can also be painted as an alternative to chrome plating. A three-layer chrome-effect paint system is a variant that BIA can offer from its own production. Of course, other finishes are also conceivable and feasible. BIA also paints components in matt black or high-gloss black. As there are virtually no limits to the color spectrum in the paint sector, the variety of colors is almost limitless. As with the BIA night design technology, combinations with laser structures and symbols are also possible for the lacquer, e.g. for translucent areas.
Depending on the requirements profile, the same tool can also be used to spray components with colored granules. This process, known as mold-in-color, is one of the most proven and simplest methods for producing monochrome through-dyed blanks. It is true that this technology or components produced on this basis are often only suitable to a limited extent for use in the automotive sector and are limited in terms of design. However, where it can be used, this alternative often offers an attractive solution, as no further processing steps are necessary.
Closing the circle again with chrome surfaces, this proven process also offers a wide range of design options, not only by changing the gloss level and tonality. In particular, the development and optimization of chrome(III) surfaces in recent years has also opened up perspectives for colour variations. Chromium(III)-based surfaces in particular can be used to create both the usual cold-bluish appearance and warm, yellowish looks. In addition, a new electrolyte for very dark shades of anthracite was put into operation at the main plant in Solingen at the beginning of 2021. The first series orders have already been placed.
Finally, there is the topic of foil back injection molding. In addition to the familiar film decors that are back-injected using ABS/PC or PC, BIA has co-developed a film for decors that is resistant and insensitive to the electroplating process, can be back-injected with an electroplatable plastic substrate and at the same time meets the test and field requirements of the automotive industry. In this way, a highly selective connection of individual foil decors and chrome-plated components can be achieved in one component without additional assembly work.
BIA also has an electroplatable film in its range. The special feature of the electroplated film co-developed by BIA is its high transmission capacity, which means that better tansmission values and improved day/night contrasts can be achieved than with conventional night design materials. This film variant is therefore best suited for ambient lighting applications and functional integration.
Thanks to all these production options, BIA offers car manufacturers an extensive portfolio of surface designs. All design options for the components are based on the same mold shape. It is true that not every component geometry is equally suitable for all processes and the desired manufacturing flexibility should be taken into account before the tool is designed. However, if these aspects are evaluated in advance and included in the design planning, BIA customers have a high degree of design freedom with a simple tool investment.
