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"By direct and fully automated linking of injection moulding, coating and final packaging with INSTANTCOAT® Plus we have reached the presently conceivable optimum in efficiency and product quality."

Dipl.-Ing. Michael Däbritz
Manager of VARIOPLAST®

There is a reduction of:
  • Material input
  • Production scrap
  • Personnel Costs
  • Cycle Time
  • Response time to problems
  • Storage time of parts before coating

Critical aspects are improvement of part quality, process repeatability and flexibility:

  • Regular coating layer thickness
  • Improved surface appearance
  • Improved coating adhesion (dirt-free parts)
  • Part defects directly recognizable during process
  • Shorter reaction time in case of malfunctions
  • Process parameters repeatable and coordinated.


2K-Injection Moulding + CO2 pre-cleaning + coating + dry + coating + dry

INSTANTCOAT®: 75% reduction of the ecological grey footprint



pdfMountingframe result sheet LCA assessment SKZ - Das Kunststoff-Zentrum


High-tech injection molding

2K-Injection Moulding + Sheet Metal Overmolding + Insert Overmolding + US-Welding + Pad Printing + polishing + Drill



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„The INLINE-metallization process INSTANTCHROME® by means of PVD, developed by VARIOPLAST®, is a perfect fit for our strategy of INHOUSE-process chains and has replaced galvanic chrome plating in our company.“
Dipl.-Ing. Michael Däbritz
Manager of VARIOPLAST®

  • The process chain of INSTANTCHROME®

    1. Injection Moulding
    2. Priming, UV-coating/drying
    3. Chrome plating (PVD-Coating)
    4. Topcoat (decorative protective coating) with solvent based and solvent free coatings, UV coating
    5. Automated packaging of the coated products

  • Advantages of INSTANTCHROME® versus galvanization process

    ● Fully automated process from injection moulding to ready-coated and packaged product
    ● Repeatable due to exactly adjustable parameters for coating and chrome plating
    ● Qualitative advantages due to constant process conditions
    ● Significantly lower scrap rate
    ● Direct part assessment during process
    ● No Hot Touch Effect
    ● Energy conservation
    ● Environmental compatibility (no hazardous waste)
    ● Cost savings

  • Applications of INSTANTCHROME®

    Decorative and functional coatings (matt and shiny)

  • Significant Advantages compared to galvanically chrome-plated parts

    ● Selective coating for fiber optics/reflector
    ● Various coating materials and polymers applicable
    ● Even snap-on hinges, clip closures, film hinges possible
    ● Ultrasonic welding, day & night design lasering feasible

  • Hochschule Karlsruhe – Bachelor Thesis at Varioplast

    Coating process of the PVC-Magnetron-Sputter process with optimization of the chrome coating by application of optimal design of experiments on the physical functionality of Magnetron Sputtering - optimal design and application of experiments (DoE) - Characteristics and Behaviour of Chrome during sputtering

  • Fulfilled Objectives

    ● no visible cracking
    ● best adherence of chrome on plastics
    ● optimization of UV-protective coating in accordance with quality standards of automobile manufacturers
    ● coating with paint (Primer/Topcoat)

Black Panel Technology

2K-Injection Moulding + Variothermie + Pad Printing + PVD-Coating + coating + US-Welding + Laser cutting