LEONHARD KURZ will be showcasing surface finishes for series production at FAKUMA 2026
Fuerth/Germany, September 22, 2026: At FAKUMA 2026, LEONHARD KURZ will be presenting manufacturing processes in Hall A4, Stand 4204, that enable decorative and functional plastic surfaces to be produced efficiently, cost-effectively and on a mass-production basis. The focus is on solutions that can reduce process steps and thus CO₂ emissions, integrate functions and enable the use of different materials. Live demonstrations at partner stands will showcase cost-effective and industrial manufacturing technologies using state-of-the-art machinery.
3K IMD process demonstrator: End-to-end process chain for new automotive front modules
A highlight of the exhibition stand is the 3K IMD process demonstrator, which illustrates how decorative surfaces, functional elements, and surface protection can be combined in a continuous manufacturing process to consolidate previously separate production steps. This can help to reduce manufacturing costs, improve process reliability, and enhance the cost-effectiveness of series production.
The technology developed by KURZ enables the manufacture of components from three different plastics, featuring both opaque and transparent areas. A key feature of the process is the IMD VARIOFORM® sheet-to-sheet technique, in which the decorative film is processed using an innovative clamping frame system. The process is suitable for components measuring up to two meters and does not require any upstream deep-drawing processes, thereby enabling energy and cost savings. With a cycle time of less than 120 seconds, a thermoplastic sheet is inserted directly into the mold and formed there under the influence of heat and vacuum.
Subsequently, using injection molding process, a transparent PC layer (K1) for the optical function, a stabilizing ABS/PC frame (K2), and a PUR protective layer (K3) featuring self-healing properties are produced using KraussMaffei’s ColorForm technology.
This energy-efficient process can be integrated into existing production lines and is suitable for the use of recycled materials. As a result, processors can benefit from a reduction in process complexity, fewer handling and manufacturing steps, and more resource-efficient production.
The front panel of the demonstrator was manufactured on a KraussMaffei machine. The materials were supplied by Sabic, Covestro and Rühl Puromer, whilst the molding technology was provided by KURZ subsidiary Schöfer.
Rear Light Concept: Lighting design for exterior use in motor vehicles
The Rear Light Concept, developed in collaboration with ams OSRAM, showcases new design possibilities for functional rear lights. The 2.5D component was manufactured in a single, highly efficient step using In-Mold Decoration (IMD). A key feature is the large-area single-image IMD design. ALIYOSTM LED films are integrated using KURZ’s downstream Functional Foil Bonding (FFB) adhesive process. Suitable for sensitive surfaces and components, this process enables the precise placement of flexible labels on 2.5D and highly curved components.
The result is a homogeneous light pattern – even with complex component geometries – whilst maintaining low energy consumption. The components used are designed for recyclability and underline the approach of modular, production-oriented vehicle development.
The Rear Light Concept was developed in collaboration with ENGEL, Röhm and Zechmayer. Other partners involved include Votteler, BAIER and Hinderer + Mühlich (H+M). The integrated mini-LED technology is supplied by ams OSRAM.
Hot Stamping: Experience efficient series production processes live
KURZ, together with its subsidiary BAIER, will be demonstrating the use of hot stamping technology live at the stand.
Hot stamping can be used to produce everything from the finest lettering and lines to multi-colored motifs, intense solid colors and precise color gradients. The thin-film technology used is designed to ensure the products are recyclable, and it is equally suitable for finishing recycled materials. Visitors can experience the hot stamping process live at the stand and gain a direct insight into this efficient technology.
Use of natural and recycled materials
In addition to process integration, KURZ is presenting material concepts featuring bio-based or recycled components for industrial plastics processing. With polypropylene-based natural fibre composites (NFPP), RECOSYS® rPET – produced from the company’s own take-back and recycling system – and the EcoLayer FX concept, the company is presenting solutions for more resource-efficient and circular production.
The use of NFPP enables the production of robust and recyclable components in which natural fiber mats are bonded directly to the decorative substrate. The mats used can consist of equal parts recycled natural fibers and recycled polypropylene. The NFPP mats are supplied by Polyvlies, a long-standing KURZ partner and specialist in technical non-wovens.
Using the RECOSYS® process, KURZ processes PET carrier residues into high-quality, single-type post-consumer recycled material (PCR) under the name RECOSYS® rPET for new applications. At the same time, the use of virgin plastics is reduced, thereby making a significant contribution to lowering the carbon footprint.
EcoLayer FX technology complements KURZ’s portfolio and enables high-quality surface decoration on substrates made from natural materials and plastics, such as talc, cellulose or limestone in combination with polypropylene. The decorative layer is finer than a human hair and is designed to preserve the component’s recyclability.
The solutions on display illustrate that high-performance plastics processing is not achieved through new materials alone, but through the interplay of material strategy, process development and industrial feasibility.
Partner projects focusing on series production
The exhibition presence is complemented by joint projects with ARBURG in Hall A3, Stand 3101, and DECKERFORM in Hall A5, Stand 5205. The application examples demonstrate how innovative surface solutions can be efficiently integrated into industrial manufacturing processes in collaboration with machine and mold partners – from process development through to near-series implementation.
