KraussMaffei Advances ColorForm: Automated In-Mould PU Coating Technology

New multi-color mixing head for automated color changes.

Reducing Setup and Material Costs with Advanced ColorForm Solutions

• New multi-color mixing head for automated color changes without interrupting the production process
• Innovative thin-layer technology: Polyurethane layer thicknesses of only 0.1 millimeters on thermoplastic components enable material savings of up to 80 percent
• Higher surface quality and further potential for resource-efficient series production

(Parsdorf, 08/25/2026) KraussMaffei is consistently advancing the development of ColorForm technology and is presenting two innovations for the in-mold coating of thermoplastic components. With a newly developed multi-color mixing head, color changes can now be carried out fully automatically and directly within the production process. At the same time, together with its long-standing development partner Siegfried Hofmann GmbH, the company has succeeded in reducing the polyurethane coating thickness to just 0.1 millimeters. Both developments increase the cost-effectiveness and flexibility of the ColorForm process and open up new fields of application for high-quality visible surfaces.

KraussMaffei is presenting a new mixing head technology for the flexible ColorForm series production of colored components. Multiple colors are available at the mixing head simultaneously and can be selected automatically during the production process without replacing color nozzles, changing color modules, or removing the mixing head. “With the new mixing head, we enable fully automatic color changes directly during the ongoing production process. This provides maximum flexibility, shortens setup times, and makes the production of variants significantly more cost-effective,” says René Dierkes, Head of Global Multi-Technology Projects at KraussMaffei.

From manual changeover to automatic color selection

Until now, a color change in ColorForm applications has required manual intervention at the mixing head. Color nozzles, color units, or color modules have to be changed. Although the process is already carried out at high speed, it still requires an interruption of the production process. The new technology eliminates this step. All required colors remain permanently connected to the mixing head. The system automatically selects the desired color while the other materials continue to circulate in the loop. The color change takes place directly within the process, quickly, reliably, and without mechanical retooling.

New thin-layer technology for a 0.1 mm PU layer thickness.

New thin-layer technology reduces material use by 80 percent

KraussMaffei and Siegfried Hofmann GmbH have reached another milestone in reducing the PU layer thickness. The two companies have been jointly advancing ColorForm technology since 2008. They have now succeeded in coating thermoplastic components directly in the injection mold with a polyurethane layer of only 0.1 millimeters. While ColorForm has previously produced high-quality, scratch-resistant surfaces with layer thicknesses of up to 0.5 millimeters, the new development enables significantly more resource-efficient production while maintaining the same high surface quality. “By reducing the PU layer thickness from 0.5 to less than 0.1 millimeters, we are achieving a major technological leap. The resulting material savings of up to 80 percent significantly reduce the material costs for each individual component,” says Andreas Bierbaumer, Technology Manager at KraussMaffei.

The reduction of the PU layer thickness to 0.1 millimeters was made possible by optimizing the component fixation, the sealing system, the preform, and the mixing head. The joint development by KraussMaffei and Hofmann thus demonstrates that ultra-thin PU layers can be produced directly in the injection mold with reliable processing and high quality. “Together with KraussMaffei, we are using the development mold to demonstrate that layer thicknesses of this kind can be achieved reliably. The design and dimensions of the tool are based on current exterior automotive components such as trim panels or diffuser lenses. At the same time, we found that the surface quality can be improved and the scrap rate reduced,” adds Stefan Hofmann, Managing Director and Owner of Siegfried Hofmann GmbH.

The new thin-layer process can be experienced live at the KraussMaffei TechCenter on a GX 650 with a spin-platen unit in combination with a mobile RimStar Compact 8/8. KraussMaffei and Hofmann will continue to jointly develop and market the technology in order to further expand the potential of in-mold coating for new applications and markets.

Premiere at Fakuma 2026

Both innovations will be presented for the first time at Fakuma 2026. Visitors will gain insights into the latest developments in ColorForm technology and learn how automated color changes and ultra-thin PU coatings can further increase flexibility and cost-effectiveness in the production of high-quality plastic surfaces.

KraussMaffei at Fakuma, October 12-16, 2026

Hall A7, Booth 7303