Decoform® technology Back Injection and Compression Moulding

Decoform ® technology
Back Injection and Compression Moulding

Compact Decoform ® manufacturing cell with
KM 420-3500 DF for boot trim panels

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Decoform ®
Back injection and compression moulding
Machine features for Decoform ® technology
Systematically engineered for premium quality
The pace of change and innovation
in the automotive sector is speeding
up, with the development time for
new models shortening year by
year. At the same time, fittings and
comfort features are becoming a
powerful factor in model and
marque differentiation. This means
that the design and quality of car
interiors play an important role in
many purchase decisions. Decoform ®
technology offers processors an
attractive method for producing
ready-decorated parts on injection
moulding machines. Precision,
repeatability and cost-effectiveness
are part of the package deal.
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Innovative production technology for
top quality decor elements: Decoform ®
A pillar trim, DaimlerChrysler B pillar trim, DaimlerChrysler
NCV2 door trim, DaimlerChrysler
Operating in a highly competitive market,
automotive companies strive to achieve
maximum differentiation under intense
cost pressure. This situation challenges
components suppliers to find innovative,
cost-cutting production methods for
high-quality moulded parts. It drives the
rapid advances in production technologies
for each new generation of cars. The
automotive industry leads the way, but
other sectors are quick to follow. The
same techniques deliver quality and cost
advantages in aircraft and train interiors
and seating, and for the furniture industry.
With Krauss-Maffei’s Decoform ® systems,
the proven quality of our engineering and
our understanding of these applications
make a big difference. Our high-performance
machines can deliver high quality
and low unit cost. Modular and upgradeable,
they are also ready for the future.
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Decoform ® – technology with quality
and cost benefits
■ Flexibility
■ High process integration cuts the
number of process steps
■ High productivity, small footprint
■ Integration of functional elements
■ Environmentally-friendly
(no solvents or adhesives)
■ Recycling-friendly products (all PP)
■ High repeatability, stable process
■ Good for the bottom line (15-30%
lower costs than conventional
laminating processes)
Manufacturing cell for door trim
with KM 250-1900 DF

C/D pillar trim, Volvo S80
KM 420-2700 DF manufacturing cell
for pillar trim (Collins & Aikman)
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Decoform ®
Back injection and back compression moulding – the differences
C pillar, VW Golf
Decoform ® back injection moulding
Decoform ® back injection is recommended
especially for narrow, elongated parts,
like pillar or door trim. A film or fabric
insert is placed in the mould. The mould
is closed and the polymer injected onto
the insert using cascade technology.
The flow front shifts from one cascade
to the next as cascade blocks are rapidly
opened and shut under the control of
the MC5 software. Each needle shut-off
nozzle is independently controlled.
Precisely regulating their activation
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Door trim panel, Peugeot 307 Door trim panel, VW Golf
eliminates the problem of folds forming
in the décor material. Pressure and temperature
damage to sensitive material
can be minimized by the right number
of cascades. With the Decoform ® module,
clamp-force build-up during injection can
be gradual, following a preset profile
which allows the mould to breathe
(depends on mould design). After the
holding pressure phase, the clamp force
can also be released in stages. This
eliminates the risk of cavity pressure
damaging the décor insert.

Chrysler Crossfire instrument panel,
DaimlerChrysler
Decoform ® back compression
moulding
Back compression moulding is especially
suitable for very large area parts with
pressure- and temperature-sensitive
décor material. Typical products are door
trim panels, instrument panel elements,
seatback shells, boot trim sections and
floormats. To keep cavity pressure as low
as possible, the clamp moves during the
injection phase.
NCV2 door trim panel, DaimlerChrysler
Field trials have shown that compression
gaps as big as 60 mm are sometimes
necessary. Gap width is closely related
to the type of décor, the thermoplastic
substrate and the gating pattern. Conventional
injection compression moulding
cannot fill the mould with repeatable
precision, because, under the influence
of gravity, the melt flows downwards
as it is injected. To achieve a repeatable
filling profile, Krauss-Maffei developed
a special compression process.
Door trim panel, Seat Ibiza
Complex design of a boot trim panel for
a new car generation
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Manufacturing cell for door trim with KM 350-1900 DF,
Johnson Controls
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Décor preheating unit integrated in the
robotic systems

Decoform ® machine features
Decoform ® clamp unit
Cavity pressures in the Decoform ® process
are far lower than in normal injection
moulding. This makes it possible to
produce large parts with relatively low
clamp force. Typical of the applicationspecific
Decoform ® clamps are the
extremely large platens and generous
opening widths.
The fully hydraulic clamp unit allows
pressure build-up in all four cylinders to
be precisely synchronized. This guarantees
that the moving platen is always exactly
parallel to the fixed platen. Pressure
and speed profiles can be programmed
with a high degree of precision and
synchronized with the injection phase.
Design and operation of the 2-platen clamp Decoform ® machines are engineered to
take larger moulds than standard injection
moulding machines
Fully hydraulic clamp guarantees
premium quality
The ideal machine for back injection
and back compression moulding has a
completely hydraulic clamp unit. This is
the only system capable of guaranteeing
precisely repeatable processes through
very tight control of position and pressure
throughout the mould closing and compression
sequences.
Decoform ® technology for standard
KM machines
Krauss-Maffei’s Decoform ® module is the
ideal hardware upgrade for standard C
and MX Series machines. It’s an option
that gives you more flexibility and better
capacity utilization for a better return on
your investment.
One keystroke calls up the Decoform ®
software module for full access to all
functions.
Optional add-ons for standard
injection moulding machines
■ Decoform ® module for all KM
injection moulding machines
■ Decoform ® clamp frame module
■ Decoform ® gripper control
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Systematically engineered for uncompromising quality
Floormats, Volvo
Displaying selected process parameters
KM 650-5700 DF for pillar trim, Montaplast
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Door trim panel, Volvo V40
Decoform ® module – a dedicated
system for perfect results
The superior technology of the Decoform ®
system sets quality benchmarks. The
most important features:
■ High-precision mould positioning
during closing, compression and
opening
■ Independent setting of compression
profile
■ Freely selectable compression force
■ Multi-stage profiles for clamp force
and closing, compression and opening
movements
■ Freely selectable clamp force build-up
and clamp speed profiles in synchrony
with injection phase
■ Graphical display shows all main
processing parameters with tolerance
range monitoring, for example:
– compression force
– screw stroke
– mould breathing
– cavity pressure
Seat component, Jaguar
More design flexibility with the
Decoform ® clamp frame module
A hydraulically controlled clamp frame is
precisely positioned in the mould. It holds
the décor in position as the mould closes
preventing slippage and folds forming.
In combination with the Decoform ®
module, the clamp frame module opens
the way to very wide freedom and
flexibility in part design.
More quality for your money
Decoform ® delivers outstanding quality
at a competitive cost with:
■ In-mould shaping of decor material
■ High repeatability
■ Successful with sensitive décor
materials (TPO/PP foambacked film
and carpets)
■ Simplified logistics
■ High productivity and a small footprint

Simultaneous insertion of decor material (left) and removal of a finished part
Manufacturing cell for pillar trim with
KM 350-1900 DF, Johnson Controls
Transfer to laser trimming unit
Laser edge trimming for pillar elements
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Creative people around the world work for Krauss-Maffei.
And for you.
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1.0 We · 1st edition 10/04 · Printed in Germany · Printed on 100% chlorine-free bleached paper · SGM 032 A PRO 10/2004 GB