Hyundai Motor Company and Kia announced on the 4th that they have succeeded in mass-producing the 'paint-free composite molding technology,' which maintains a smooth vehicle body surface and secures high strength without the conventional painting process.
This manufacturing method was first applied to the roof spoiler of Hyundai's electrification business platform model, the 'ST1 Cargo.' Paint-free composite molding technology is a next-generation manufacturing method that uses plastic composites to produce vehicle exterior parts without separate painting work.
The most notable feature of this method is that it uses a color raw material with laminated transparent and color layers to replace the conventional automotive painting process. This maximizes carbon emission reduction during production.
ST1 roof spoiler with multi-material molding technology applied (highlighted in yellow in the photo. The original color matches the vehicle) [Photo by Hyundai Motor Company·Kia]
First, the color-coated raw material is heated to soften it, then placed on a mold to form the exterior shape of the roof spoiler. To secure strength beyond a certain level, thermosetting materials such as polyurethane and glass fibers are applied inside the molded part, followed by pressing it again with the mold to complete the final product.
Previously, painting and sanding processes identical to body painting were required to manufacture the roof spoiler, but with paint-free composite molding technology, these steps can be omitted. Painting plants consume about 40% of the energy used in automobile manufacturing processes, requiring significant energy.
In terms of quality, this technology offers advantages such as glossiness and uniform yet rich color expression. Since color raw materials are used, even if minor damage occurs, the original color remains intact at the damaged area.
Moreover, the composite materials applied in this technology are more than 20% lighter than the fiber-reinforced plastics conventionally used, contributing to improved energy efficiency.
A Hyundai Motor Company and Kia representative stated, "The paint-free composite molding method is the result of Hyundai Motor Group's manufacturing technology research aimed at providing customized mobility tailored to customers' preferences and purposes. Through innovation in manufacturing methods, we will secure production flexibility and high product quality while contributing to energy use reduction."
© The Asia Business Daily(www.asiae.co.kr). All rights reserved.
