At K 2025, KraussMaffei, together with partners Leonhard Kurz and Rühl, will unveil the "FrontIQ Light" headlight, manufactured with ColorForm technology that unites design, function and protection in a single process. At the core of the demonstrator is an inline polyurethane surface applied directly to thermoplastic parts inside the injection mold. This approach replaces conventional hard coating with a PUR layer that protects against UV exposure, stone chipping and chemicals. The coating thickness can be adjusted with a precision of one tenth of a millimeter. Depending on specification, the surface can provide different haptic effects and a self-healing effect for fine scratches. A mold-integrated film deep-drawing step shapes printed films three-dimensionally in the cavity. An automation solution cleans the films in advance, positions them accurately and heats them with a gripper to enable deep drawing. The heating concept ensures extremely uniform temperature distribution and a precise fit in the mold. Decorative films printed using thin-film technology are back-injected in a sheet-to-sheet process with transparent and black polycarbonate, enabling depth effects, individual surface structures and durable protection created directly in the mold without subsequent painting. KraussMaffei supplies ColorForm as a turnkey cell covering automation, PUR processing and injection molding, so design, function and the protective layer are created in one fully integrated step. The technology will be shown live on a GXW 650 with a reversible plate, and a 3K demonstrator in the design of a 720 millimeter headlight will be on display at the Leonhard Kurz booth in hall 5, A19.
ColorForm-based inline coating and design integration
The ColorForm process applies a precise PUR surface directly onto thermoplastic substrates within the injection mold, combining protection and optical finish without secondary coating operations. The PUR layer can be tailored to the application, including variable tactile effects and the ability to mitigate fine scratches. According to KraussMaffei, the approach expands styling latitude while consolidating steps into a single, networked manufacturing cell.
"With our ColorForm technology, KraussMaffei is revolutionizing front lights: from design freedom with printed films to precise 3D forming, all in one intelligently networked complete solution," explains Dr. Frank Szimmat, Managing Director KraussMaffei Technologies.
The design concept merges several thermoplastics with a decorative film and a PUR surface. Films printed using thin-film technology are back-injected via a sheet-to-sheet sequence with transparent and black polycarbonate, enabling brilliant depth effects and individual surface patterns. "Automotive design today is more expressive and emotional than ever before. With concepts such as \"FrontIQ Light,\" we are taking design to the next level, seamless, sustainable, and full of new possibilities. Light becomes a language. Surfaces become a brand experience," says Luitpold Haarländer, Head of Sales Management Automotive at Leonhard Kurz.
FrontIQ Light, the front headlight manufactured by KraussMaffei with ColorForm technology.
Mold-integrated film deep drawing and automation
The mold-integrated film deep-drawing process is presented as a world first. The film is formed in 3D directly in the mold, enabling a broad range of effects from elegant depth to distinctive patterns. Precision and repeatability are supported by automation that cleans the films upfront, positions them exactly and provides controlled heating via the gripper to make deep drawing possible. The solution ensures extremely uniform heating of the film for maximum quality and an exact fit in the cavity. Despite the process complexity, the cell is designed to run smoothly with all steps delivered from a single source.
Turnkey scope and trade fair demonstration
KraussMaffei delivers ColorForm as an integrated package that combines automation, PUR processing and injection molding into a fully connected workflow. Design, functional integration and protective surface are produced directly in the mold without additional rework. At K 2025, visitors will be able to see the setup live on a GXW 650 equipped with a reversible plate. A 3K demonstrator styled as a 720 millimeter headlight will also be shown at the Leonhard Kurz booth in hall 5, A19.
ColorForm technology
