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Nachrichten, Termine, Experten
Nachrichten, Termine, Experten
Hof – The joint research project InMIDoor conducted by Hof University of Applied Sciences, KKT-Norsystec and Roos GmbH has developed an innovative approach to vehicle doors. Instead of installing numerous individual components such as switches, levers and complex electronics, the new interior door panel integrates all control elements into a single, flexible surface. The result is a lightweight, sustainable and intuitive solution.
“Our goal was to combine functionality, sustainability and design in one single component. The technology we developed makes it possible to integrate touch functions into flexible, bio-based plastics – a combination that is unique to date,” explains project leader Prof. Dr. Thomas Meins.
Research for the Mobility of the Future
This was achieved by developing a novel injection-molding process that allows capacitive control elements to be integrated into three-dimensionally formed plastic surfaces. Conventional mechanical switches are thus replaced by flat, robust and aesthetically pleasing surfaces. The technology is based on so-called Mechatronic Integrated Devices (MIDs), which combine electrical and mechanical functions within a single plastic component.
Sustainable Materials and Innovative Conductive Inks
To this end, Hof University and its partners developed new conductive printing inks based on alternative particles such as silver, copper and graphite. These inks were applied to polypropylene films using a screen-printing process. The films were then formed using a high-pressure forming process and subsequently back-molded with natural-fiber-reinforced biopolymers. The result is an interior panel that is both environmentally friendly and highly functional. The researchers tested various combinations of film materials, adhesion promoters and conductive inks in order to optimize bonding strength and electrical conductivity.
Polypropylene is increasingly used in the automotive industry because it is lightweight, sustainable and versatile. It reduces vehicle weight, lowers CO₂ emissions and is also a cost-efficient material that can be recycled easily. “The biggest challenge of the project was developing a conductive ink that can undergo significant deformation without losing its functionality. The interaction between material, printing process and curing was crucial,” explains Christian Roos, Managing Director of Roos GmbH.
From the Laboratory to Application
After numerous forming and injection-molding trials, a demonstrator component was produced: an armrest with an integrated heating function and capacitive touch surfaces. The result is a functional, lightweight and resource-efficient component that could set new standards in vehicle interior architecture.
“The door of the future responds to touch instead of button presses,” summarizes Frank Schollmayer of KKT-Norsystec. “And it is made of materials that significantly reduce our consumption of resources.”
“With InMIDoor, we demonstrate how scientific findings can be transferred directly into industrial practice,” emphasizes Prof. Dr. Meins. “This is how innovations are created that are convincing not only technologically, but also ecologically.”
Future Perspectives
The innovative manufacturing technology, which combines injection molding, film integration and capacitive control functions, has the potential to revolutionize the production of state-of-the-art components with a wide range of applications in industries such as aerospace, rail transport, medical technology and automotive engineering. At the heart of this approach is an advanced manufacturing process: precise injection molding combined with sustainable carrier materials such as natural-fiber-reinforced polypropylene enables the production of complex, durable and environmentally friendly components. The integration of films and capacitive control elements creates smooth, easy-to-clean surfaces that meet the highest hygiene and design standards. The process is characterized by high resource efficiency, promotes the use of recyclable components and significantly reduces the ecological footprint. With a projected market potential of up to €6.5 million per year in series production, this technology underscores its role as a forward-looking solution.
Funding
The InMIDoor project was funded under the ZIM program of the German Federal Ministry for Economic Affairs and Climate Action and ran from June 2022 to May 2025.
Prof. Dr. Thomas Meins
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