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In-Mold Coating: Smart coatings for premium automotive designs
Revolutionizing automotive surfaces with Direct Coating, the In-Mold Coating (IMC) technology. One-step process, very high yield, endless design possibilities – how material and technology create innovation.
Story · September 2, 2025
The Material Effect
Direct Coating revolutionizes surface finishing by applying coatings directly within the injection mold. Our proven expertise in simulation, processing capabilities, and tailored substrates and coating raw materials ensures efficient project realization. This expertise enables seamless technology adoption globally. With our partners, we transform ordinary surfaces into extraordinary masterpieces.
The Technology: In-Mold Coating for innovative automotive applications
Our Direct Coating process as IMC technology is a smart combination of injection molding with reaction injection molding in a single mold:
- Makrolon®, Makroblend® or Bayblend® is injected
- A reactive polyurethane coating system based on raw materials Desmophen® and Desmodur® overmolds the thermoplastic in a second cavity
The result is a finished, coated part with aesthetic surfaces in one efficient process - eliminating numerous production steps and near-zero emissions of Volatile Organic Compounds (VOCs) with superior part quality for innovative mobility concepts.
How material and technology enable new automotive applications
Recent material developments now further extend the options for automotive industry to create innovative design options acting as differentiator. In combination with highly automated processing chains and optimized coating systems, individualized mobility solutions for premium and mass applications can be achieved through lean value chains by a one-step coating process.
Experience laser-individualized in-mold coated parts:
- Striking light and depth effects by 3D surface structures integrated into adhesion-optimized Makrolon® IMC2477 available in numerous colors
- Seamless logo and design integration without disrupting surface defects by specialized IMC systems that change color and translucence with laser activation
- All achieved with minimal equipment and near-zero rejection rates by in-mold coating
Discover the possibilities of combining film insert molding with in-mold coating technology:
- Adhesion-optimized Makrolon® IMC2477 enabling design features like depth effects through 3D structures with integrated frame and mounting system by 2K injection molding
- Pre-printed Makrofol® films delivering highly individualized design options with the potential to integrate heating options for autonomous driving sensors
- Self-healing automotive coating surfaces through PUR as transparent protection layer
A partnership approach along the entire value chain
Covestro delivers more than materials - we provide comprehensive support from concept to mass production:
- Expert guidance in part design and simulation
- Global molding trial facilities and mass production launch assistance
- Multiple patents and state-of-the-art development centers worldwide
- Partner network of machine manufacturers, mold makers, coating suppliers & Tiers
Key benefits
Efficiency:
Less production steps and energy consumption compared to conventional processes
Superior Quality:
No orange peel effect, homogeneous finishes, high dimension stability
Sustainability:
Near-zero VOC emissions and reduced scrap rates
Cost Effectiveness:
Low investment in equipment, single-operator capability
Design Freedom:
3D structure replication, integrated tactile elements, self-healing properties