PARSDORF, Germany, Aug 31, 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 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.
About KraussMaffei – Pioneering Plastics
KraussMaffei is among the world’s leading manufacturers of machinery and systems for the production and processing of plastics and rubber. Our brand stands for cutting-edge technologies – for more than 185 years. Our range of services covers all areas of injection molding machinery, extrusion technology, reaction process machinery and automation. In 2022 we added additive manufacturing to our portfolio. This broad range of technologies gives KraussMaffei a unique selling point in the industry. With the high innovative power of our standardized and individual product, process, digital and service solutions, we can guarantee customers sustained additional value over the entire value-adding chain. Our range of products and services allow us to serve customers in many sectors including the automotive, packaging, medical and construction industries, as well as manufacturers of electrical and electronic products and household appliances.
KraussMaffei employs around 4.200 people all over the world. With more than 30 subsidiaries and over 10 production plants, as well as about 570 commercial and service partners, we are represented internationally close to our customers. The company was founded in 1838 in Munich. Today, KraussMaffei is part of Sinochem Holdings Corporation Ltd., one of the world’s leading chemical companies. For more information, visit www.kraussmaffei.com.
