09,05,2026 7 views
When consumers sit in a new car, their first impression of "luxury" is often formed at the moment when their fingertips swipe over the wood trim of the center console or their gaze sweeps over the coherent texture of the integrated dashboard.
However, for automotive interior manufacturers, achieving a perfect decorative effect with high-end texture on complex irregular surfaces while balancing cost and efficiency has been a long-standing technological challenge. The traditional INS insert injection molding process often falls short when faced with complex shapes such as bidirectional large arcs and deep inverted buckles, while preserving the original tactile sensation.
How can we bridge the gap between design and mass production? The DOD process introduced by DeKomo, also known as TOM Three Dimension Overlay Method, is becoming the "golden key" to solving this problem.
1、 Industry challenges
Interior decoration technology is facing three common challenges
With the fierce competition in the automotive industry, high-quality interiors have become the core competitiveness, and "large curved surfaces, integration, and high-end feel" have become the mainstream trend. However, the bottleneck of traditional craftsmanship is becoming increasingly prominent, making it difficult to meet the upgrading needs, which is driving many enterprises to actively seek technological innovation and breakthroughs.
1 |The game between styling upgrade and surface tactile sensation
The integrated interior and surround design have become standard for high-end models, but the INS process membrane is subjected to two high temperatures and high pressure impacts, causing the surface of the membrane to have a touch of oil, micrometer level concave convex wood grain/leather grain, which is directly "ironed out" by pressure in a high-temperature softening state. Microscopic peaks and valleys are compressed, the concave convex drop is reduced, and the touch is severely weakened or disappeared.
2 |The contradiction between cost reduction demands and quality upgrades
On one hand, automobile manufacturers continue to lower prices, while interior manufacturers strictly control costs; On one hand, consumers' demands for wood grain, skin texture, and unity are constantly increasing, and low-end craftsmanship can no longer support product positioning. Many companies are trapped in the "unit price theory" when choosing models, only seeing that the unit price of the membrane may be lower, but ignoring itmoldHidden expenses such as investment, yield loss, and rework costs ultimately result in higher overall costs and sacrifice of product quality.
3 |The conflict between rapid iteration requirements and traditional mass production rigidity
At present, the cycle of vehicle model updates has been significantly shortened from three years to one and a half years, with annual models, special editions, and personalized color schemes emerging one after another. In the face of such high-frequency iterations, traditional INS technology seems inadequate: replacing a texture requires synchronously updating the vacuum forming mold, cutting blade mold, andInjection moldNot only is the cost of small-scale production extremely high, but frequent switching of production lines also leads to slow response and high hidden costs.
In contrast, the DOD (TOM) process exhibits great flexibility advantages: it only requires one-time injection molding of materials for storage, and can be flexibly produced according to order requirements, perfectly adapting to the fast iteration mode of "small batch, multiple varieties".
2、 Process comparison
Embedded injection molding vs 3D vacuum coating
Many people's understanding of the two processes remains at the level of 'one inside the mold, one outside the mold', but all the differences in appearance, cost, and efficiency fundamentally stem from the underlying logic.
1 |INS mold embedded sheet injection molding
The full name is Film Insert Molding, which belongs to the in mold integrated composite process. The process is to first vacuum form the printed decorative film, cut it into a shape that matches the part, and then put it into an injection mold.
The heat transferred from the plastic at a temperature of 220-240 ℃ on the back during injection molding heats up the surface of the film again with the touch ink/touch oil. Ordinary touch oil has limited heat resistance, and after heating, the three-dimensional convex structure melts and collapses, causing micro concave convex loss and weakening or disappearance of texture.
2 |DOD (TOM) three-dimensional vacuum coating
It belongs to the post mold decoration process. The process is to first inject the plastic substrate normally, and then place the decorative film into the laminating equipment. Through the positive and negative pressure of vacuum, the film is evenly adhered and wrapped on the outer surface of the part, and finally the decoration is completed.
Summary in one sentence: INS is "make film first, then inject plastic, and integrate molding"; DOD (TOM) means "first making the substrate, then laminating, and later decorating".
3 |There are various differences between the two processes:
• Quality performance:
DOD (TOM) wins in styling freedom, INS wins in long-term durability
The DOD (TOM) process is not constrained by injection molding and can perfectly adapt to irregular bidirectional surfaces, deep inverted buckles, and sharp corner structures; It can also achieve 360 ° circular reverse wrapping, with the side walls completely covered without plastic bare edges, and the overall sense of unity is extremely strong.
The core advantage of INS is the integration of film and substrate, high adhesion reliability, but the shortcomings are also very obvious, such as easy deformation of deep curved surfaces and weak three-dimensional layering of wood grain, making it difficult to create advanced texture effects.
• Cost Truth:
DOD (TOM) offers higher overall cost-effectiveness, while INS trades quantity for price
Early development stage: INS requires three sets of molds, including vacuum forming molds, cutting blade molds, and injection molds, with extremely high investment in large molds; DOD (TOM) only requires conventional injection molds and simple laminating fixtures, with a development investment 40%~60% lower than INS, and the trial and error threshold for new projects is extremely low.
Production end: Currently, the unit price of DOD (TOM) film is about 5% higher than INS film, but it has fewer processes, stable yield, and lower rework costs. The comprehensive cost of irregular and oversized parts is actually better.
If there is ink flushing or positioning deviation in INS, the entire piece will be scrapped; Defects in DOD (TOM) film coating can be torn off and reused, and the substrate can be reused. The difference in scrap cost between the two is significant. INS needs to rely on a large number of orders to dilute costs and bring back its overall cost disadvantage.
Efficiency showdown:
DOD (TOM) has agile response and fast iteration, while INS is difficult to cope with multiple varieties
DOD (TOM) only has two main processes of base material injection molding and vacuum coating, with a standard beat of 120 seconds, which can produce more than one the first mock examination, and its comprehensive efficiency is higher than INS; Strong adaptability to large and small batches, and easy implementation of fully automated production, with obvious response advantages for multi variety and fast iteration projects.
INS includes 5 independent processes with a single cycle time of 90-130 seconds, highly dependent on manual precision film placement, and the cost of automation transformation is high; Changing models requires synchronous replacement of multiple sets of molds, which is a tedious process and carries a high risk of stockpiling. It is only suitable for stable car models with high annual sales.
3、 Selection of Applications
There is no standard answer for selection, the key lies in equipment capability
There is no absolute superiority or inferiority in process selection, the core is to adapt to project requirements, which depends on the specific application scenario:
1 |Prioritize INS scenarios
• Flat/shallow arc workpieces;
• Height positioning requirements.
2 |Prioritize selecting scenes with DOD (TOM)
Interior parts with bidirectional large curvature, irregular structure, and deep inverted buckle, INS technology cannot meet the styling requirements;
Quick redesign, multiple varieties and small batches, requiring flexible texture switching for projects;
• Preserve high-quality surface texture;
Projects with small initial investment and lower overall cost in the later stage;
New projects that require rapid prototyping and quick implementation.
At present, the mainstream industry adopts a "combination strategy": core visual components are created with DOD (TOM) to create high-end texture, and flat small components are created with INS or water transfer printing. But many companies choose the right process, but due to insufficient equipment accuracy, problems such as deep surface wrinkles, edge rebound, and poor batch consistency occur.
In fact, the technological advantages of DOD (TOM) must rely on high-precision equipment to truly land. DeKomo has deeply cultivated differential pressure coating technology and made multiple core optimizations to meet the strict standards of automotive interiors.
•Multi functional control system:Accurately control the pressure timing for deep cavities, large drops, and sharp corners to ensure even coverage of the membrane and significantly reduce the yield of wrinkles and complex curved surfaces in the industry;
• Partition independent temperature control system:Match films of different materials and thicknesses to ensure consistent texture and gloss during mass production;
• Fully automated compatible design:Can be paired with an automatic film feederManipulatorUp and down pick-up, further compressing the pace and reducing manual dependence;
Excellent vacuum value and pressure holding function:Ensure that the entire surface of the film material is tightly wrapped, without bubbles or bulges, to ensure consistency in appearance.
Choosing the right process is choosing the right direction, and choosing the right equipment is the key to truly transforming process advantages into product competitiveness and cost advantages.
4、 Industry Outlook
Under the upgrade of texture, the popularity of DOD (TOM) is inevitable
The competition in automotive interiors has already entered the stage of "quality competition", and integration, personalization, and rapid iteration will become the core development direction in the future.
Under this trend, DOD (TOM) 3D vacuum coating technology is gradually sinking from high-end models and becoming the mainstream choice for interior decoration, thanks to its high degree of modeling freedom, short development cycle, and flexible model changes. The technological progress of domestic laminating equipment is also continuously lowering the threshold for process implementation, promoting the upgrading of interior quality throughout the industry.
Dekemo will also continue to refine its differential pressure coating technology, relying on the mature service experience of over 50 repeat customers. From equipment research and development to process support, we will provide a complete set of practical solutions for interior enterprises, and work together with the industry to promote the upgrading of interior decoration technology.
