Automotive roof system supplier Webasto AG in Stockdorf, Germany, is now operating three injection molding machines for polycarbonate glazing, and plans to add more.
At the IAA 2011 automotive industry fair in Frankfurt, Joachim Damasky, Webasto chief technology officer and director for global comfort systems, said a second KraussMaffei polycarbonate glazing injection molding machine was installed at its Schierling, Germany, plant in mid-2011.
That means Webasto is now running three glazing machines in Schierling. The first 2,700-metric-ton machine from Battenfeld was installed in 2007 to mold the Smart fortwo roof starting in 2008. The second, 2,300-tonne unit from KraussMaffei was added in 2009.
Webasto Chairman Franz-Josef Kortüm said the firm received eight new series production orders during 2009, taking the company to 90 percent utilization of its 160,000 roofs/year capacity and 60 percent of its siloxane wet-coating line capacity.
Looking ahead, Damasky said there are now plans to add one or two more PC-glazing molding machines and that move would require a second coating line.
The company began using PUR composite spray molding (PUR-CSM) in 2011. Equipment from Hennecke was installed in Schierling to produce interior roof slides, said Holger Engelmann, Webasto vice chairman and director for convertible, roof and body activities.
Webasto's show exhibit featured a concept car with a sliding PC roof with integrated solar cells. For IAA 2011, Webasto had achieved Class A surface quality on the PUR-CSM roof part with painted-in-body color. But the firm was still working to find a cost-effective means of preventing PUR vapor emission from affecting the paint surface under production conditions, Damasky said.
The complete roof module on the concept car weighed 44 pounds and made use of Bayer's Makrolon AG2677 PC for the glazing panel part of the roof.