Hyundai Motor and Kia have successfully achieved mass production of their ‘paintless composite molding technology’ that maintains a smooth vehicle body surface while ensuring high levels of strength without the need for conventional painting processes.
This manufacturing method was first applied to the roof spoiler of Hyundai’s electrified business platform model, the ‘ST1 Cargo.’
Paintless composite molding technology is a next-generation manufacturing process that utilizes plastic composites to produce exterior vehicle parts without the need for additional painting operations.
The most notable feature of this technique is its use of color raw materials layered with transparent and color layers to maximize the reduction in carbon emissions during the production process, replacing the conventional automotive painting process.
Initially, the colored raw material is heated to soften it, which is then placed onto a mold to create the exterior shape of the roof spoiler.
To secure the necessary strength, a thermosetting material of polyurethane and fiberglass is applied inside the molded shape, followed by a pressing process with the mold to complete the final product.
Previously, producing a roof spoiler required the same painting and sanding processes associated with body painting, but the paintless composite molding technology allows for the omission of these painting processes. The body painting factories consume up to 40% of the total energy used in automotive manufacturing processes.
In terms of paint quality, there are advantages like higher levels of gloss compared to conventional painting techniques, as well as the ability to achieve uniform and rich color representation. Since color raw materials are used, even if minor damage occurs, the color of the damaged area remains intact.
Moreover, the composite materials applied in this technology are more than 20% lighter than traditional materials such as Fiber Reinforced Plastic (FRP), aiding in the improvement of fuel efficiency.
Hyundai and Kia believe that the paintless composite material technology, with its high molding freedom and diverse color implementation, can be widely used in parts that require small-lot, high-variety production.
There are plans to further develop the paintless composite molding technology to be applied in the production of body parts such as hood panels, meeting a variety of consumer needs.
A Hyundai Motor and Kia official stated, “The paintless composite molding technique is a product of Hyundai Motor Group’s manufacturing technology research aimed at providing customized mobility that meets customer preferences and purposes. We will strive to secure production flexibility and high product value through innovation in manufacturing processes while contributing to energy conservation.”
Lee Sang-jin daedusj@autodiary.kr