Efficient production of a high-quality radio key cover
The cover of a radio 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 technology (Protective Layer Finish) 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 back-moulded and the decorative film is applied to the plastic surface. The cover is punched 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 both material usage and process effort. The product is recyclable. Different films with various designs and colours can be used flexibly for product variants.
A Kuka six-axis robot is used for handling the radio 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, the radio key cover is freed of chips and finally placed on a conveyor belt by the six-axis robot and discharged from the production cell.