Automotive Interior Special Effects
The Challenge
The client was spray-painting automotive interior trim parts to achieve a premium metallic finish, a process that was slow, wasteful, and environmentally costly. Paint defects and VOC emissions were pushing costs up and jeopardizing the program's sustainability targets.
- Spray painting produced high VOC emissions and regulatory exposure
- 20% reject rate from paint defects and uneven coverage
- Long production cycle times reduced line throughput
- Metallic finish had to match across PP, ABS, and PC/ABS parts
- Need to eliminate secondary painting without sacrificing appearance
Our Solution
MHK Color developed a custom metallic masterbatch using aluminum flake pigment in a PA carrier matched to the client's base polymers, achieving the same visual effect in a single injection molding step.
- Aluminum flake pigment in a polymer-matched carrier for metallic luster
- Single-step injection molding eliminates the painting process entirely
- Color matched across PP, ABS, and PC/ABS within Delta E below 1.0
- Formulation engineered to preserve flow and surface quality in thin-wall parts
- Full OEM approval with APQP and PPAP documentation
Results Achieved
The switch from spray painting to metallic masterbatch delivered dramatic cost, quality, and environmental improvements while matching the original appearance specification.
- Zero VOC emissions achieved
- Reject rate dropped from 20% to under 2%
- Production cycle time reduced by 40%
- Overall cost per part decreased by 35% including material and process savings
Key Results
Products Used
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