German automotive giant Daimler (Stuttgart; www.daimler.com) has developed a manufacturing process for series production of very lightweight trim parts for motor vehicles. The “KIS” technology combines intelligent compression and injection moulding processes to achieve claimed weight reductions of up to 50%.

With the new process, the company benefits from the best of both process worlds: the pressed components allow a marked reduction in weight with the injection-moulded components incorporating the ribs to ensure stability and strength as well as providing a broad scope for shaping the production of a wide range of components.

In the process, ribs and attachment points are injected directly onto the pressed carrier while it is still hot. The starting material for the carrier is a hybrid bonded-fibre fabric consisting of thermoplastic and reinforcing fibres. Using the same materials for the bonded-fibre fabric and the injection-moulding process results in an optimum bond, claims the company, adding that the KIS process allows both simple functional integration and low wall thicknesses.

Weight savings of more than 5 kg per vehicle can be achieved thus allowing for a reduced material input, Daimler states. The result translates into a reduction in CO₂ emissions from the component manufacturing process. The first parts for pillar and door trims to be produced with the KIS process are set for series production in one of the company's next model lines.