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FrontIQ Light

Injection-molded headlights with a PUR coating

Product information

The FrontIQ Light headlamp represents the next generation of automotive lighting systems. This innovative solution combines design, functionality, and surface protection in a single manufacturing process—made possible by ColorForm technology, which incorporates a PUR coating during the injection molding process.

A revolution in headlight manufacturing

Unlike conventional headlights, which require multiple process steps such as painting and hard coating, FrontIQ Light integrates all functions directly into the mold. Through the use of in-mold coating, thermoplastic components are finished with a high-quality polyurethane (PU) surface immediately after injection molding. This replaces energy- and material-intensive processes and makes production significantly more efficient.
 
The result: a more sustainable, cost-efficient, and high-quality production of automotive components with high-gloss, scratch-resistant, and durable surfaces—without any downstream painting processes.
 
Advantages of FrontIQ Light at a glance:
 
  • Combines design, function, and protection in a single process
  • High-quality, scratch-resistant surface thanks to an integrated PUR coating
  • Eliminates traditional painting steps → reduced production costs and cycle times
  • Perfect for demanding automotive applications and visible components

What makes the FrontIQ Light so special?

FrontIQ Light Explainer Video

Technology in detail – In-Mold Coating with PUR:

 
At the heart of the FrontIQ Light is the combination of:
 
 
  • Thermoplastic base material
  • Decorative film
  • In-line applied polyurethane (PUR) surface
 
With in-mold coating, the protective layer is applied directly in the injection mold. This completely replaces traditional hard coating and provides reliable protection against UV radiation, stone chips, and chemicals. Additionally, the PUR layer enables precise control of surface properties down to the tenth of a millimeter, as well as self-healing effects for fine scratches.
 
 

Unique process integration in injection molding

 
A particular innovation is mold-integrated film thermoforming.
 
In this process, the decorative film is three-dimensionally formed directly in the mold, enabling precise positioning through automated handling and uniform heating for maximum fit accuracy. This globally unique combination enables fully integrated production, where design, function, and surface finish are created in a single process.
 
 

Sustainability and efficiency

 

ColorForm technology enables the sustainable and cost-effective production of automotive components such as the FrontIQ Light and offers numerous ecological and functional advantages:

  • Reduction of CO₂ emissions by up to 30% through optimized process integration in injection molding
  • Complete elimination of solvents and traditional painting processes, thereby eliminating environmentally harmful paint waste
  • Significant reduction in material consumption, transportation costs, and scrap rates throughout the entire production chain
  • New design possibilities for brand-specific lighting signatures through innovative, vertically structured lighting architectures
  • Enhanced functional integration through the combination of multiple manufacturing steps into a single process
  • Reduced weight of components, which contributes to improved energy efficiency in the vehicle

FrontIQ Light enables a 51% reduction in costs

Any questions? Our experts will be happy to advise you.

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Why choose ColorForm for automotive components?

ColorForm enables the cost-effective production of high-quality, innovative solutions such as the FrontIQ Light. The technology offers an efficient alternative to traditional plastic painting while also enabling new design possibilities and functional surfaces.

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