Design under the bonnet

The Weber Group, a full-service supplier of plastic components and systems, is producing an engine cover with a sporting design for the BMW 2 Active Tourer, which was launched in autumn 2014.

Motorabdeckung BMW Rückseite
Motorabdeckung BMW Vorderseite

Optimale Akustik und Formstabilität

Motorabdeckung des BMW 2er Active Tourer mit hochwertigem Druckbild

The specialist in plastics solutions is realising the new engine cover from development to series production. A particular challenge here was in developing the retainers adequately with respect to demoulding and the wall thickness of the ribs.

All the components of the engine cover are produced and assembled in Weber's main plant in Dillenburg. This involves, for example, bonding the contours of moulded polyurethane foam to those of the plastic element and form-fitting the BMW emblem. Besides functional properties such as optimised acoustics and dimensional stability, the new cover for the BMW 2 Active Tourer is also distinguished by its high-quality appearance. For this purpose, the polyamide plastic used is enhanced with a delicate print image consisting of the BMW logo, TwinPower Turbo lettering and five design stripes.

In order to produce the high-quality covers, Weber uses a 2-component print process that reduces the cycle times and thereby manufacturing costs by using an electromagnetic sliding table specially designed for production. An automatic removal mechanism transports the injection-moulded plastic part to the sliding table, which can move along X and Y axes. The different print images with differing height and angle profiles can be printed in a one process step thanks to a multiple printing plate that holds three individual printing plates each with the relevant print image.