The  wide uptake of electric vehicles (EVs) is driving a transformation in automotive lighting design. Unlike conventional vehicles, EVs have fewer mechanical components, which results in more available space within the vehicle structure. Additionally, EVs often utilize advanced electrical systems and lightweight materials, providing automotive designers with greater flexibility in integrating lighting elements. Consequently, OEM designers can seamlessly incorporate lighting features into various aspects of EVs, including ambient lighting in the interior, controls, and displays, as well as exterior panels and decorative elements, thereby enhancing both aesthetic appeal and functionality.

A top priority for car brands is the incorporation of LED-driven brand logo components; lighting emblems that can achieve a 3D chrome effect (with laminated product of Makrofol® Film and Toray’s PICASUS™ Film)* or a black panel (with Makrofol® LM296) look, or good UV resistance (with Makrofol® UV244), depending on the conditions. Moreover, all of these innovations must be feasible for mass production.

*Laminated product of Makrofol® Film and Toray’s PICASUS™ Film is under development product

CCL Design is a component producer which acquired McGavigan Holdings Ltd., another leading supplier of in-mold elements for automotive interiors. Their collaborative effort aimed to demonstrate to automotive designers how film insert molding technology (FIM), also known as in-mold labeling (IML), can be combined with various films to meet the evolving requirements of future car designs, especially for front panels and radomes.

To produce a demonstrator LED lighting emblem that achieves the desired 3D chrome effect, these companies engaged Niebling GmbH, a pioneer in high-pressure film insert molding. This, coupled with our own expertise in films and polycarbonates engineered specifically for FIM technology, formed a comprehensive partnership spanning the value chain. 

The technical challenge was to produce a high-quality demonstrator lighting emblem component capable of achieving a variety of visual effects. This capability depended greatly on the type and position of backlighting as well as general ambient light. Simultaneously, it needed to be well-suited for mass production using film insert molding.

This lighting emblem needed to simulate a logo with a floating 3D chrome effect under specific conditions. In particular case, it had to display a metallic effect without any light and then reveal greater embedded detail when illuminated from the back or the side.

The entire multi-layer design itself required precise printing and critical forming registration during the molding processes. Any films used had to strike an optimal balance of formability, weatherability, chemical resistance, UV stability, durability, and excellent aesthetics. Crucially, the final demonstrator component had to accommodate functions  like a built-in defroster.

To  achieve the required 3D effects along with full functionality, the molding stack comprised three layers of decorated Makrofol® Films separated by spacers, designs for use in FIM tools engineered by Niebling GmbH.

The top and bottom film layers contained the matrix combination of metallic film, black panel film, and transparent films to achieve the specified effects. The logo itself was printed and formed on the middle layer. This stack of pre-labelled foils and spacers was then injected into the mold, enabling different effects to be generated depending on the light sources and position. The stack was back-molded with Makrolon® AG2744. Depending on the choice of film, the lighting emblem could integrate a fully functional defroster. It is also possible to engineer LiDAR transparency where surfaces are flat.

This demonstrator project illustrates the potential of film insert molding and confirms that FIM technology can fulfill the future needs of automotive OEMs for exterior front panels and radome covers.