Engel Cuts Automotive Manufacturing Emissions by 60 Percent

At a Glance

• Engel’s clearmelt process floods components with polyurethane directly in the mold, producing Class A automotive surfaces without painting.

• The technology reduces CO₂ emissions by up to 60% compared to conventional painting lines.

• Single-source responsibility through the Engel Clearmelt Competence Center simplifies project coordination and reduces risk.

• The BMW iX kidney grille marks the first large-scale series application of this exterior surface technology.

More than 300 automotive industry professionals, engineers, and decision-makers from across Europe, North America, and Asia gathered recently in northern Italy to witness a breakthrough in vehicle manufacturing: a technology that promises to eliminate one of the most expensive, energy-intensive, and carbon-heavy steps in car production, the paint line.

From June 29 to July 2, 2026, Engel hosted its Surface Innovation Days at the facilities of mold-making specialist INEVO in San Polo di Piave. The event showcased the full industrial maturity of the company’s clearmelt process, demonstrated live on an Engel duo 4000 combi M two-platen injection molding machine with 40,000 kN of clamping force. The system combines multiple production steps into a single machine, enabling manufacturers to produce large-format exterior components with high-quality, durable surfaces directly in the mold, removing the need for any subsequent painting, coating, or polishing operations.

A Game-Changer for Sustainability and Cost

The environmental and economic implications are significant. Conventional automotive paint lines account for roughly 30–40% of total CO₂ emissions generated during vehicle assembly, according to industry data. They also require massive upfront capital investment, extensive floor space, complex ventilation and drying systems, and ongoing maintenance, energy, and chemical costs.

By replacing these entire workflows, Engel’s clearmelt technology cuts CO₂ emissions by up to 60%, while simultaneously eliminating the need to build and operate dedicated paint facilities. This delivers a double benefit: a drastically reduced carbon footprint and a substantial lowering of both capital expenditure and long-term operating costs.

“Painting has long been seen as an unavoidable part of automotive manufacturing necessary for protection and appearance, but costly and environmentally demanding,” said Clemens Kastner, PhD, Head of Business Development Automotive & Mobility at Engel. “Today, we are proving that it is no longer the only way. The clearmelt process delivers better performance, shorter production chains, and far lower emissions.”

How the Technology Works

At the heart of the system is the turning-platen design of the Engel duo combi M machine, which allows multiple processes to be carried out in sequence within the same mold. The production flow demonstrated at the event followed these steps:

1. An ENGEL Easix articulated robot places a colored 2D film into the mold cavity. Integrated infrared heaters warm and soften the material, which is then thermoformed to match the shape of the component.

2. A second film carrying decorative elements, brand emblems, or functional features is inserted and formed into a shallower contour.

3. Both films are then back‑molded with polypropylene or another thermoplastic substrate, creating the structural part.

4. The central platen rotates, moving the formed component into a second station where the surface is flooded with a specially formulated polyurethane (PUR) system.

5. The material cures rapidly inside the mold, forming a smooth, continuous, and durable Class A finish.

The result is a surface that is not only visually flawless but also highly scratch‑resistant, UV‑stable, weatherproof, and chemically resistant. It even features self‑healing properties, allowing minor surface marks to disappear naturally at room temperature over time.

Beyond appearance and durability, the technology unlocks new design possibilities. Functional films can be embedded directly into the surface, enabling radar and LiDAR transparency, integrated lighting, or sensor housings without disrupting the visual continuity of the vehicle exterior. Changing colors or finishes between production runs is also faster and simpler than with traditional paint lines, supporting greater flexibility in manufacturing.

Simplifying Complexity: The Competence Center

One of the biggest barriers to adopting advanced surface technologies has traditionally been organizational complexity. Processors and OEMs had to coordinate separately with injection molding machine suppliers, polyurethane material providers, metering system specialists, and mold makers, leading to high coordination costs, technical interface risks, and longer lead times.

To solve this, Engel established the clearmelt Competence Center (CCC), which acts as a single source of responsibility for the entire solution. From the initial feasibility study and design consultation through mold development, material selection, process validation, and full‑scale series production, customers have one point of contact and one accountable partner.

“Our goal is to reduce uncertainty,” Kastner explained. “When you bring together machine technology, mold expertise, metering systems, and material science under one roof, you eliminate communication gaps and reduce the risk of delays or quality issues.”

The CCC operates globally, with teams in Europe, North America, and Asia working in close collaboration. In‑house testing facilities include an Engel duo 5500 with 55,000 kN of clamping force at the company’s headquarters in St. Valentin, Austria, as well as additional capacity in Schwertberg and at partner locations around the world. This allows manufacturers to run trials with their specific component designs and materials under real‑world conditions before making large‑scale investments.

Proving Industrial Readiness

The live demonstration at INEVO confirmed that the technology is ready for high‑volume production. The machine produced a large exterior module combining a bumper, air intake, and front‑end panel — parts that would normally be molded, painted, and assembled separately. By integrating them into a single unit, the process reduces assembly steps, cuts inventory needs, and improves overall part consistency.

“Functional integration is a top priority for automakers today,” said Andreas Popp, Managing Director at INEVO Germany. “Exterior components are no longer just panels; they are housing sensors, cameras, lighting, and cooling systems. The clearmelt process lets us combine all these functions while delivering a finish that meets the highest visual and mechanical standards.”

This capability has already moved from concept to reality. The BMW iX kidney grille is the first major exterior application to reach full series production using clearmelt technology. Following this success, manufacturers are now developing new uses across roof modules, hoods, doors, and full front‑ and rear‑end assemblies.

Material and Process Evolution

Advancements in material science have also accelerated adoption. Polypropylene, widely used in automotive construction for its low weight, cost efficiency, and safety performance, is now fully compatible with the PUR flooding process. Polyurethane layers have been optimized to be thinner while maintaining full protection, reducing material consumption, and further lowering the environmental footprint.

Suppliers such as Borealis and Mankiewicz are working closely with Engel to develop substrate and coating systems tailored to the technology, ensuring adhesion, durability, and compliance with global automotive standards.

A Clear Path Forward

For automotive manufacturers looking to meet tighter emissions regulations, reduce production costs, and increase design flexibility, the clearmelt process offers a clear, proven alternative. By removing painting from the process chain, the industry gains a solution that is not only more sustainable but also more efficient and adaptable to the demands of modern vehicle design.

As interest grows across markets, the combination of reliable machine technology, a unified support structure through the Competence Center, and successful real‑world applications positions Engel’s innovation as a key step toward the future of automotive manufacturing.