Smart Panels - personalized and intuitive driving experience

Smart panels have become an integral part of our everyday lives. In building management, for example, smart panels can be used for energy management by controlling lighting, heating and other systems based on environmental conditions or resident preferences. In the automotive industry, customization, comfort and safety play a central role. Smart panels allow car owners to customize their vehicles according to their style and preferences while also increasing road safety.

In the exterior sector, smart panels enable the integration of customizable elements such as dynamic lighting designs that can change color and patterns. These technologies also open up new possibilities for innovative displays, such as welcome messages or status indicators, which can be projected directly onto the car’s body. For example, they can display the battery charge level on electric vehicles.

In the interior sector, customization significantly expands the possibilities for interior design. Smart panels allow elements such as the dashboard, center console, and door panels to be equipped with interactive surfaces that respond to touch and integrate various functions, including lighting, information, and even entertainment. Users can change the colors and appearance of these elements to match their mood or create the desired ambience.

Depending on the application and the use of smart panels in automotive exteriors and interiors, injection molding offers numerous possibilities for the production of smart panels. Everything is possible, from back-injection of films in standard injection molding to multi-component injection molding with integrated films and flooding with polyurethane to produce scratch-resistant surfaces.

The use of the right injection molding processes plays a crucial role:

• combimelt: Enables the direct production of assembly elements by combining two or more plastic materials.

• foilmelt: Provides design flexibility by allowing easy changes to the film design. The integration of electronics into the film is also possible.

• clearmelt: Flooding of surfaces directly in the process with a scratch-resistant and UV-resistant layer of polyurethane, eliminating the need for subsequent painting.

For all injection molding processes, the same principle applies: At the end of an injection molding cycle, a fully finished component is produced, ready for direct installation in the car.

ENGEL systems enable the production of smart panels in a continuous process. This results in greater efficiency and cost-effectiveness, as there is no need for extensive post-processing or painting stations.

Specific machine and automation solutions are used depending on the desired properties of the smart panel. The system or layer structure are always adapted to the final product.

A layer structure is clearly demonstrated using the example of a "rear-end cover":

1. A decorative film is back-injected with a dark plastic using the ENGEL foilmelt process.

2. In the subsequent combimelt process, a second, transparent thermoplastic layer is applied, allowing for the future integration of lighting elements.

This injection molding cycle not only enables the production of complex geometries, but also simplifies the subsequent assembly of components. For example, by simultaneously manufacturing mounting features such as retaining clips and similar elements. The film design can be easily changed, which offers significant advantages in terms of design flexibility and customization.

The size of the component determines the size or tonnage of the machine. The two-platen machine duo is the ideal choice for the production of smart panels. With a standard clamping force range of up to 5,500 tons, large components can be produced. However, even significantly larger machines have been built for specific customer requirements. Additionally, the ENGEL duo is ideally equipped for all injection molding processes.

Reliable partners in mold making, film production and material supply are just as crucial as the injection molding machine. ENGEL cooperates with renowned companies in these industries and has built up a strong network over the years. Customers receive support from the initial concept to the production of the first parts and beyond. This enables us to precisely address the specific needs of our customers.

To give customers the opportunity to test or sample complex parts and processes, ENGEL provides a duo 5,500 combi M with a clamping force of 55,000 kN at its customer technology center in St. Valentin. This machine is equipped with three injection units and is prepared for various injection molding processes. Molds with a total weight of up to 150 tons can be installed. This marks a clear commitment to ENGEL's expertise in the production of complex large components and its strong customer-oriented approach, providing comprehensive support throughout the realization process.

The future of smart panels is promising, especially in the context of increasing digitalization and technological advancements in various industries. Smart panels can be further enhanced with advanced technologies such as OLED displays and sensors, as well as interactive surfaces. These innovations would enable even more intuitive and seamless interactions, such as gesture-based controls or panels that respond to environmental changes like light and temperature.

This would also make future smart panels even more customizable, with adaptive designs or dynamic displays that adjust to user preferences or external conditions. This would not only enhance usability, but also increase efficiency.