Turnkey system for flexible overmolding of inserts Produce "turnkey" products with high-quality covers

At K 2025, Arburg presented a fully automated production cell for manufacturing automotive products with high-quality designs and finishes. The system combines injection molding technology with in-mold decoration (IMD) and a new PLF (Protective Layer Finish) technology.

A turnkey system centered around a new Allrounder 475 V demonstrated for the first time at K 2025 how products with high-quality designs and surfaces for the mobility industry can be efficiently manufactured. Using the example of fully automated production of high-quality covers for car key fobs, Arburg demonstrated how new machine technology, an innovative IMD (in-mold decoration) process, and a new PLF (protective layer finish) technology work together.

Case Study: Remote Key Cover

The demonstrator is the cover of a car key fob, whose design is based on the “Generic Smart Key” from Huf, a supplier of access systems for automakers. The final product features integrated sensors, connectivity with digital devices, and anti-theft protection.

In addition, the surfaces meet high standards for design, tactile feel, durability, and radio compatibility. This is where Leonhard Kurz comes in: The plastic cover, made from a post-industrial recycled material (PIR) based on PC/ABS, is produced using the new PLF technology for in-mold decoration (IMD) in combination with a textured mold insert.

First, a wafer-thin PET film—including the decorative layer—is fed into the mold from the outside via a feeding device. There, the film is back-injected, applying the decorative film to the plastic surface. The mold is supplied by Kurz subsidiary Schöfer; the standard mold components are from Meusburger; the mold insert design is by Reichle; and the hot runner technology is provided by Witosa.

The cover is die-cut into a rectangular shape while still in the mold, and the remaining film is rolled up within the vertical machine's working area. No subsequent coating is required, and the product is recyclable. For product variants, different films with various designs and colors can be used flexibly.

Vertical machine that can be flexibly automated

The vertical injection molding machine used can be flexibly automated, for example with linear Multilift systems or six-axis robots. Arburg supplies these turnkey systems, including peripherals, as CE-compliant complete systems from a single source.

In the trade show application, a Kuka six-axis robot equipped with a Barth gripper system handled all part handling. The robot retrieves the injection-molded part and feeds it to a Rea laser station, which marks the component with a code. The part is then transferred to a Barth milling station to remove excess material and create the final contour. A Kist + Escherich cleaning station then removes any chips from the cover before it is discharged via a conveyor belt.

A key aspect for processors is their involvement in the R-Cycle initiative. The laser-based code on the component allows recycling-related data—such as material composition—to be stored in a digital product passport. This creates the transparency needed for closed-loop material cycles and meets future regulatory requirements for plastic products.

Simple and intuitive: The new Gestica Lite control system

The machine is equipped with the “Gestica lite” control system, which is designed for ease of use. A central dashboard displays information about the current job, the ongoing process, and upcoming tasks. Optional assistance functions also actively support staff in ensuring the quality of the plasticizing and injection-molded parts.

Vertical machine: energy-efficient and capable of automation

The Allrounder 475 V has a clamping force of 1,000 kN and is specifically designed for standard applications, such as e-mobility, electronics, and medical technology. These include the manual or automated overmolding of cables, connectors, and infusion accessories.

The standard Arburg servo-hydraulic system (ASH) continuously adjusts the power output of the water-cooled, speed-controlled servo motors to meet demand. This reduces specific energy consumption by up to 60% compared to conventional hydraulic machines.

Despite its compact footprint, the machine offers space for larger tools. The standard installation height of 250 mm can be optionally extended by up to 200 mm. A closing cylinder positioned higher up and side doors improve access to the tool compartment. The table height is set at 900 mm to ensure ergonomic operation.

The Allrounder 475 V vertical machine has been available since early 2026.