Hennecke to Demonstrate Clearmelt Technology for Scratch-Resistant Resilient Functional Surfaces for Automotive Exteriors

At CAMX 2023, Hennecke will demonstrate Clearmelt technology, a technology that combines polycarbonate injection molding with polyurethane overflow injection. It coats thermoplastic substrates with clear or colored polyurethane to provide scratch-resistant, resilient and functional surfaces for consumer products and automotive exteriors. The achievement stems from a partnership with mechanical equipment manufacturer Engel, which uses Clearmelt technology to protect all-electric BMWs
The signature kidney-shaped front module of the iX.

Originally a radiator grille, BMW’s kidney grille now protects the cameras and sensors of electronic assistance systems that allow semi-autonomous driving. In order to accommodate these enhanced functions, the structure of the front module and its production process have been significantly adjusted. Since 2009, Hennecke and Engel have been working together to develop the new solution, utilizing Hennecke’s expertise in polyurethane applications, with Engel as the main contractor.

Following a survey in 2018, Hennecke and Engel developed a tailor-made solution for BMW’s Landshut plant in Germany with the participation of suppliers, tool manufacturers and cleanroom experts. In a clean room environment, thermoplastic molded parts are produced by injection molding and coated in a subsequent process step. Because the polyurethane coating is both aesthetically pleasing and protective, no additional surface preparation is required. The self-healing properties of the urethane coating can take care of minor damage, ensuring the car maintains its flawless appearance over time.

The benefits offered by polyurethane coatings are not limited to scratch resistance, but include transparency for sensor visibility and a smooth, depth-enhanced surface. The technology allows for different surface structures and thicknesses within a single component, demonstrating BMW’s commitment to sustainability by minimizing waste. In addition to Clearmelt technology, Hennecke
Also offers additional high-quality functional surface solutions for the automotive industry.