Live demonstrations at K 2025: LEONHARD KURZ shapes innovations together with strong partners

Fürth/Germany, October 1, 2025: Whether decoration, function, or sustainable design: At K 2025, LEONHARD KURZ will not only be showcasing visionary surface solutions, but also demonstrating how they are created in near-series processes. Together with its subsidiaries and long-standing partners, the specialist for thin-film technology will be represented at several exhibition stands. The focus will be on live applications on state-of-the-art machines – manufacturing and finishing everything from complex automotive front panel modules and sustainable natural fiber components to decorated organic pots.

Live at the KURZ booth: Highly integrated 3K process for components with PUR surfaces

At booth A19 in Hall 5, KURZ will be producing one of its automotive highlights live. The complete front panel of the FrontIQ Light Concept will be manufactured on a GXW 650 from KraussMaffei. The over 12-meter-long system with PUR unit combines a 3K injection molding process with KURZ decoration and polyurethane surface in a continuous process for the first time. The resulting demonstrator was developed in cooperation with SWAROVSKI Mobility and the lighting system development specialist SP3. It is manufactured using injection molding materials from Sabic, film material from Covestro, and PUR compound from Rühl Puromer. KURZ subsidiary Schöfer, in turn, provides the high-end tool technology that enables the component to be produced in a single, highly efficient process step.

3K IMD: The process in detail

This advanced technology allows components to be manufactured from three different plastics – with opaque and transparent sections. A key feature of the process is the underlying VARIOFORM sheet-to-sheet technology, in which the decorative film is processed using an innovative clamping frame system. The process allows component sizes of up to two meters and eliminates the need for upstream thermoforming processes, saving both energy and costs. The cycle time is less than 120 seconds. A thermoplastic sheet is inserted directly into the mold and shaped using heat and vacuum pressure. In the next step, a transparent PC layer (K1) is applied to the plastic casting using injection molding technology, which enables the optical functionality. A stabilizing frame made of black ABS/PC (K2) is then injection molded. Finally, the decorated module is flooded with a PUR layer (K3), which protects the decor, the microstructures, and the radar-permeable areas. The energy-efficient process can be integrated into existing production lines and is suitable for processing recycled materials.

Light integration for automotive exterior rear lights using Functional Foil Bonding Adhesive for sensitive components

KURZ will also be demonstrating the application of LED foils using the Functional Foil Bonding (FFB) Adhesive process at its booth. Together with ams OSRAM, a functional light component with IMD decoration is being developed using ALIYOS^™ technology. This process, which is suitable for sensitive surfaces and components, allows flexible labels to be placed on 2.5D or highly curved components. Unlike traditional optical bonding or lamination processes, FFB Adhesive enables greater automation, faster processes, and optimized production, as the application process can be controlled separately. In addition to ams OSRAM, KURZ subsidiary H+M is involved with high-quality embossing tools, as are other partners.

ENGEL: IMD decoration

At the ENGEL booth (Hall 15, Booth C58/B42), the REAR Light Concept cover will be manufactured live on a duo 700 using IMD decoration – a project that was realized in collaboration with Röhm and Zechmayer. Polymethyl methacrylate (PMMA) from Röhm is used for this purpose, which is processed with the injection molding tool from Zechmayer. In addition, polyurethane (PUR) from Votteler is used to functionally refine the component surface. The final integration of the lighting technology will take place afterwards at the KURZ booth on a machine from BAIER. The hot stamping tools used are from Hinderer + Mühlich (H+M), a company that also belongs to the KURZ Group.

Decoration variety for tubes and glass – from digital printing to Conical inLINE FOILING

A third highlight is provided by KURZ subsidiary ISIMAT, a leading manufacturer of machines for decorating glass, tubes, and plastic items. The KURZ booth will feature a live presentation of the combination of Direct Digital Decoration (DDD) and Conical inLINE FOILING (CiF) – on a sustainable jar made of bioplastic from Weimako, packaged in paper packaging from Sappi.

As the world's only provider of Conical inLINE FOILING, ISIMAT is setting new standards in conical metallization: Even complex shapes can now be decorated with 360-degree metallization thanks to wrinkle-free foil finishing. Direct Digital Decoration also enables personalized motifs and high-resolution designs – seamlessly integrated into industrial printing processes. The ISIMAT I series supports these applications with intuitive operation, quick-change systems, and a throughput of up to 80 pots per minute.

WITTMANN: Natural fibers as a lightweight construction solution

At booth B22 in hall 15, WITTMANN, in cooperation with KURZ, will demonstrate the production of a component made of natural fiber-reinforced polypropylene (NFPP). The system processes the material on a vertical injection molding machine, whereby the natural fiber is inserted as a fleece and then over molded. The component produced impressively demonstrates how a synergy of sustainable and intelligent material solutions with attractive surface designs is possible. The nonwoven technology comes from POLYVLIES, essential components of the ISOSPORT decor system, and the tool from FRIMO. The process offers potential for applications in vehicle interiors and other industries where weight, design, and sustainability are equally important.

ARBURG: Performance meets process integration

At the ARBURG stand (Hall 13, Stand A13-2), a high-quality Performance Car Key is being created that combines design, function, and protection in a single component. It is being produced on a newly developed ALLROUNDER 475 V vertical injection molding machine. The smart key is made from PIR (Post-Industrial Recyclate) from Sysplast Nuremberg. An innovative mold from Schöfer is used, which employs the new PLF (Protective Layer Finishing) technology from KURZ. Together with an exclusive laser structure from the Reichle Technology Center, this exhibit demonstrates the economical and efficient evolution of the IMD decoration approach. The project impressively illustrates how different haptic, functional, and optical requirements can be efficiently implemented in a single component through sensible and well-thought-out process integration. For this project, the automotive supplier Huf Hülsbeck & Fürst created the key design, Meusburger supplied the standard parts and tool design, and the hot runner system came from Witosa.

Closed recycling loop

KURZ's presence at K 2025 will be rounded off by a trade fair highlight that combines visionary surfaces with the highest sustainability standards: Uniquely designed jerseys made from KURZ's own recycled PET (rPET). The RECOSYS^® rPET used comes from the world's first take-back and recycling system for PET transfer materials from the graphics industry, which was developed and is continuously optimized by KURZ. The rPET available through this process, which is sorted by type, can be processed into textile fibers, but can also be used for other everyday products. The jerseys now presented as prototypes are an example of the diverse applications of RECOSYS^® rPET in the textile industry. KURZ is currently working on scalable solutions to meet the growing demands of the industry, once again underlining its pioneering role in sustainability.

At a glance

K 2025 from October 8 to 15, 2025, in Düsseldorf
LEONHARD KURZ Stiftung & Co. KG: Hall 5, Booth A19
Focus of the trade fair presentation: Exterior Design, Interior Design, Visionary Design, Sustainability