Hennecke's Clearmelt technology revolutionizes the automotive industry by enabling scratch-resistant, transparent surfaces with self-healing properties.
The BMW kidney grille has been redesigned to protect sensors and cameras for semi-autonomous driving, benefiting from this innovative technology.
Hennecke and Engel have been collaborating for over a decade to develop and implement pioneering solutions in the field of polyurethane applications.
Hennecke Inc. Revolutionizes the Automotive Industry with Clearmelt Technology.
Hennecke Inc., based in Bridgeville, Pennsylvania, proudly showcases the groundbreaking Clearmelt technology, enabling an impressive fusion of polycarbonate injection molding with polyurethane flood injection. This innovative method coats thermoplastic substrates with transparent or colored polyurethane, creating scratch-resistant, resilient, and functional surfaces for consumer goods and automotive exteriors.
This achievement stems from a collaboration with machine manufacturer Engel, where Clearmelt technology was introduced to safeguard the iconic kidney-shaped front module of the all-electric BMW iX.
Originally designed as a radiator grille, the BMW kidney grille now shields the cameras and sensors of electronic assistance systems enabling semi-autonomous driving. To accommodate these enhanced features, both the structure and the production process of the front module underwent significant alterations.
Since 2009, Hennecke and Engel have been working together to pioneer new solutions, with Engel serving as the primary contractor, benefiting from Hennecke's expertise in polyurethane applications.
Following an inquiry in 2018, Hennecke and Engel, with input from suppliers, toolmakers, and cleanroom experts, developed a tailored solution for BMW's Landshut plant in Germany.
In a cleanroom environment, a heated functional film is back-molded with polycarbonate, flood-injected with polyurethane, and promptly prepared for further processing. This eliminates the need for additional surface finishing, thanks to the dual-function polyurethane coating that provides aesthetics and protection. Its self-healing properties counter minor damages, ensuring the car's flawless appearance over time.
Polyurethane flood injection offers benefits beyond scratch resistance, including transparency for sensor visibility and a glossy, depth-enhancing surface. This technique permits diverse surface structures and thicknesses within a single piece, underscoring BMW's commitment to sustainability by minimizing waste.
In addition to Clearmelt, Hennecke provides other high-quality, functional surface solutions for the automotive sector.
