Smart Door


Individualization & functional enhancement in automotive industry (40.000 individualized vehicles per day at VW)


Variant diversity with decreasing batch sizes


Differentiation and increased efficiency of production by means of printing and laser processes using the example of printed conductor lines/cable harnesses, sensors and control elements of a car door 

Results Smart Door

In a car door, operating elements were integrated as printed switches and lighting, and an electric motor was electrically contacted on aluminum and plastic surfaces. Thereby, robot-guided dispensing or inkjet printing processes are used. A new process is also used to apply copper wire lines together with an insulating sheath directly to the component. This saves the standard installation of a cable harness segment.

Production Technologies for Functional Integration


  • Economic approach to the individualization of mass-produced products  


Successful Functionalization of Metallic Components


  • Printing of robust and deformable insulation layers and conducting paths on aluminum, which are still functional after metal forming
  • Connection technology between print sample and standard connection


Successful Functionalization of Thermoplastic Components


■ Printing of electrodes and piezo-active layers for pressure-sensitive button applications and LED lighting

■ Digital production of through holes (vias) by laser

■ Digital production of connection interfaces

■ Lighting simulation for individualized button layouts


Hybrid Integration of Ultrasonic Transducers for Near Field Sensing


■ Application of piezo elements on aluminium sheets

■ Optimization of resonance frequency and sound pressure level by laser ablation of the metallic substrate

■ Maximum sound pressure level at 38,9 kHz applicable as ultrasonic proximity switch


Printing on 3D Objects with Robot Technology


■ Robot-controlled printing technology for the production of conductive tracks on 3D objects

■ Closed CAD-CAM chain for fast exchange of print layouts on 3D objects