Leonhard Kurz: Integrated Surface Finishing and Material Concepts

(Photo: Leonhard Kurz).

At Fakuma 2026, Leonhard Kurz is showcasing processes for the decorative and functional finishing of plastic surfaces. The focus is on integrating multiple manufacturing steps, combining different plastics, and using recyclates and natural fibre composites. Demonstrators for front modules and rear lights illustrate automotive applications.

(Photo: Leonhard Kurz).

A three-component IMD process demonstrator combines decoration, optical functions and surface protection in a continuous manufacturing sequence. It is based on the “IMD Varioform” sheet-to-sheet technology with a clamping frame system. A thermoplastic sheet is placed directly into the mould and formed using heat and vacuum, eliminating a separate upstream thermoforming process. According to the company, the process is suitable for components up to two metres in size, with a cycle time of less than 120 seconds.

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The three plastic components perform different functions: a transparent polycarbonate layer forms the optical component, while an ABS/PC frame stabilises the part. Subsequent PUR overmoulding using KraussMaffei’s “ColorForm” technology creates a protective surface that Kurz describes as having self-healing properties. The process is designed for integration into existing production lines and to allow the use of recycled materials. The front panel was manufactured on a KraussMaffei system. The materials are supplied by Sabic, Covestro and Rühl Puromer, while the mould technology comes from Kurz subsidiary Schöfer.

(Photo: Leonhard Kurz).

With the “Rear Light Concept”, developed jointly with ams Osram, Kurz is presenting a concept for functional automotive rear lights. The 2.5D component, including a large-area single-image decoration, is manufactured using in-mould decoration. The “Aliyos” LED films are subsequently integrated using the “Functional Foil Bonding Adhesive” process. This allows flexible labels to be applied to 2.5D and highly curved components. The mini-LED technology comes from ams Osram. Other project partners include Engel, Röhm, Zechmayer, Votteler, Baier and Hinderer + Mühlich. According to Kurz, the components are designed for recyclability.

At its own stand, Kurz is demonstrating hot stamping together with its subsidiary Baier. The process enables the transfer of fine lettering and lines, as well as multicoloured motifs and colour gradients. According to the company, the thin-film technology used is also suitable for finishing recycled materials and is designed to preserve product recyclability.

Another focus is on polypropylene-based natural fibre composites (NFPP). In this process, natural fibre mats are bonded directly to the decoration carrier. The mats supplied by partner Polyvlies can consist of 50 percent recycled natural fibres and 50 percent recycled polypropylene.

Kurz is also showcasing “Recosys rPET”, obtained through its own take-back and recycling system. In the “Recosys” process, PET carrier residues are converted into single-polymer recyclate for new applications. The “EcoLayer FX” technology enables surface decoration on substrates that combine polypropylene with materials such as talc, cellulose or limestone. The thin decorative layer is intended to preserve the recyclability of the component.

Further applications are being showcased jointly with Arburg in Hall A3, Stand 3101, and Deckerform in Hall A5, Stand 5205 (see plasticker news dated 26 September 2026). These partner projects focus on integrating surface finishing processes into industrial manufacturing.

Fakuma 2026
Friedrichshafen, Germany
12–16 October 2026
Hall A4, Stand 4204

More information: www.kurz-world.com, www.kurz.de

Leonhard Kurz Stiftung & Co. KG, Fürth, Germany

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