Affordable Luxury: Premium Automotive Materials for Mass Market Vehicles

The need for affordable mobility solutions

The automotive industry currently faces challenging demands for mass market affordability of electric vehicles with the need to differentiate with exceptional aesthetics and innovative design solutions for automotive applications. Furthermore, new Automotive OEMs are entering the market and seeking solutions that don't require high investments in equipment while still enabling visually appealing surface types.

With our materials optimized for premium automotive surface finishes through various surface technologies, Covestro can deliver affordable luxury designs while addressing critical industry pain points with solutions for both established and emerging markets.

The Technology: Premium surface finishes for Polycarbonates

Conventional spray and flow coating processes enable cost effective high-quality solutions for mass market applications in existing automotive coating values chains – using optimized Polycarbonates as key component for highly aesthetic designs.

Our Direct Coating process furthermore is an efficient In-Mold Coating (IMC) technology combining injection molding with reaction injection molding of Polyurethane coatings in a single mold:

1. Makrolon®, Makroblend® or Bayblend® is injected into the mold as substrate component
2. A reactive polyurethane coating system based on raw materials Desmophen® and Desmodur® overmolds the thermoplastic in a second cavity

The result is a finished part in a single production step - creating premium appearances for mass market automotive surfaces with low market entry burdens based on Covestro materials.

How material and technology enable affordable luxury

Recent material developments have pushed the boundaries of premium surface finish technologies in automotive mass market applications, encompassing both conventional spray and flow coating processes as well as in-mold coating technology.

How Makrolon® AG extends design options for conventional coating value chains:

• 3D structures to create innovative design features are directly integrated during injection molding
• Makrolon® AG solutions with color-neutral light transmission between 5%-75% and UV stabilization allow for customizable depth effects
• Established conventional coating processes enable various color options on the back of the component, and act as a transparent scratch resistant protective layer on the front side 
• Efficient use of existing coating equipment for innovative premium designs in mass-market automotive solutions

How In-Mold Coating reduces market entry burdens for affordable luxury solutions for automotive industry:

• Molded-in-color metallic effects are achieved by adhesion optimized Bayblend® and Makrolon® IMC solutions
• Integrated 3D structures as design features and adjustable visual depth effects 
• Smooth surface finish and protection are provided via transparent scratch resistant PUR In-Mold Coating with self-healing effect
• Low market entry burdens for suppliers of mass market applications through low investment costs and efficient production processes in one single step

Beyond material solutions: A Partnership Approach

Covestro delivers more than materials - we provide comprehensive support along the entire value chain:

• Excellent network across the entire value chain for automotive applications
• Expert assistance in part design as well as mechanical & rheological simulations
• Global expertise in injection molding, In-Mold Coating and conventional hard coating technologies
• Component testing and R&D capabilities for application optimizations
• Dedicated support for mass production launches
• Multiple patents and state-of-the-art development centers worldwide

Visit us at K2025 to experience firsthand how our material innovations are transforming automotive surfaces—proving that the material effect delivers affordable luxury to the mass market.