Engineered Products

Laser Texturing and Coating

Wear-Resistant Functional Structures through a Combination of Laser Texturing and PVD-Coating

The combination of state-of-the-art laser texturing and optimized mold temperature control opens up completely new possibilities for design and functional features in plastic articles. The combination of femto laser technology and conformal cooling enables robust and reproducible molding of microstructures thanks to a significantly more homogeneous temperature distribution.

A specially adapted PVD coating effectively protects the textures from abrasive wear and guarantees a long service life – without compromising on function. This makes it possible to create large-area functional textures that not only improve the feel but also optimize the ergonomics of the end product.

PVD Coating for Durable Textures

PVD coatings are applied in a high-vacuum environment by vaporizing metal and introducing a reactive gas simultaneously. At voestalpine eifeler Coating, layers between 2 and 8 µm thick can be deposited at varying temperatures, starting from 200 °C. By integrating texturing with PVD coating in a unified engineering process, the wear resistance of even the most delicate textures can be enhanced without compromising molding precision. This was used to protect the high-gloss surfaces and the fine soft-touch textures, the Digimarc code and hologram features within the voestalpine COFFEE CUP MOLD.

To protect the delicate microstructures on the COFFEE CUP and LID MOLDS surfaces from wear, the eifeler CHROME-X® coating was applied. Unlike conventional coating systems used in plastic injection molding, CHROME-X effectively maintains the gloss level of the tool surface. Its gloss retention properties enable superior mold surface replication, even for intricate and finely detailed structures.

Compared to arc-evaporated PVD coatings, CHROME-X—applied via magnetron sputtering—offers several technological advantages. It is deposited at low temperatures (< 250°C) and requires no post-treatment, thanks to its dense, droplet-free growth. This results in a hard, smooth coating with reduced roughness, leading to significant benefits in plastic injection molding, such as minimized material adhesion and improved demolding performance. Additionally, CHROME-X is certified as a food-safe coating.

New Functional Features Through Microstructures

Laser texturing, when combined with optimally adapted cavity temperature, allows for the creation of innovative design and functional features in the plastic surface. By integrating femto laser technology with conformal cooling, the process achieves robust and reproducible molding of microstructures, thanks to the uniform temperature distribution. Additionally, a tailored PVD coating protects these textures from abrasive wear, ensuring long-lasting tool performance without compromising functionality.

This approach enables the application of functional textures like the soft-touch characteristc across large surface areas (shown in the images), significantly improving the tactile quality, ergonomics, and overall appearance of the molded parts.

Image below: Microscopic image of the functional texture showing the height profile of the microstructure

Sustainability through Innovative Design Features

The innovative use of microstructures in the cup design achieves a premium look and feel without the need for a second elastomer component. This approach not only enhances recyclability but also significantly reduces tooling costs. The textural contrast between the inside and outside of the voestalpine COFFEE CUP highlights the effectiveness of this design.

By leveraging femto laser technology, conformal cooling, and advanced coating techniques, the microtextures are replicated with exceptional precision and consistency. This also enables the integration of a hidden Digimarc watermark within the functional texture. Users can scan this invisible watermark with an app to access detailed product information.

To explore this cutting-edge technology further, simply download the Digimarc app (Android, Apple) and scan the watermarks embedded in the cup and lid.