Efficient production of high-quality remote key covers
The cover of a remote key serves as the demonstrator at FAKUMA 2026. A post-industrial recyclate (PIR) based on PC/ABS is processed. A high-quality surface is produced using the PLF (Protective Layer Finish) technology for in-mould decoration (IMD) from partner Leonhard Kurz in combination with a structured mould insert. This technology does not use conventional transfer systems, but rather a thin PET carrier that remains permanently on the component. In the mould, the film is subjected to in-mould lamination, thereby applying the decorative film to the plastic surface. The cover is cut out in a rectangular shape in the mould, and the remaining film is wound up in the build chamber of the vertical machine. Additional protective coatings are not required, reducing material consumption and process effort. The product is recyclable. Different films with various designs and colors can be used flexibly for product variants.
A Kuka six-axis robot is used for handling the remote key cover. It removes the moulded part from the mould and transfers it to a laser station, where it is marked with a code. In a subsequent cleaning station, chips are removed from the remote key cover and it is then placed on a conveyor belt by the six-axis robot and removed from the production cell.