Dolphin Interior Trim Components

The new multi-phase Dolphin process allows a rigid substrate with integral foam core and MIC grained skin to be produced in one step on one machine. Equipped with an opposing, 2-barrel rotary platen with expansion / decompression option and utilizing the microcellular foam molding process, the system molds a rigid PC/ABS carrier, then forms a solid, MIC grained Class A outer skin (thickness adjustable by manipulating mold cooling time) as well as a low-density foam core layer (thickness / density are adjustable by altering the mold opening stops) from the same shot of TPE.  The 3 layers maintain a strong bond without need for corona treatment.  The parts reduced cost 25% vs. the previous PVC slush-molded option, reduced process steps from 8 to 2, eliminated waste (since scrap from the all-thermoplastic system is fully recyclable and can be ground and reused).

OEM/Vehicle Daimler AG 2011MY Mercedez-Benz  Actros System Supplier Sole SpA Material Processor Trexel Inc. ENGEL Austria GmbH

Material Supplier SO.F.TER. SpA Resin Pibiflex polyester based TPE Tooling/Equipment Supplier Georg Kaufmann AG

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