Elegant, strong but lightweight; components from Scherer & Trier for the new Porsche Cayman and Cayman S
Trunk-space trim components for the Porsche Cayman S
Classic design, back injection molded

The Porsche Cayman S was voted "2006 World Performance Car" at the New York International Auto Show. Scherer & Trier developed three components for this sports car that have real metallic designer surfaces. A novel fabrication technique for combining back injection molding technique with stainless steel inserts was brought to maturity to accomplish this.

Midway through 2004, Porsche inquired at Scherer & Trier about the development of three components that were to appear in the Porsche Cayman S in November of 2005. These were to form the trim for the trunk space mid-section, as well as, a cover frame for the service well and its integrated release button. Porsche requested that only original materials should be used. All of these parts were to have a stainless steel surface and were to represent an interior continuation of the ideal line of the Porsche design. Even though the fabrication technique for these had to be developed from scratch, a decision was made to use back injection molding technique in combination with stainless steel inserts. "I was glad to manage a project of this magnitude which involved such major production ramifications. The challenges of a completely new process and the high customer demands for design and technology made this project particularly exciting", explained Project Manager Markus Rößler. This development secures progressive expertise for Scherer & Trier in dealing with insert technology. This technique was successfully brought to maturity when the fitting work was performed for these exclusive components in the Michelau plant.

Back injection molding technology with advantages
Stainless steel insert technology has profound advantages for fabrication. With respect to design, it offers the value perception of a solid stainless steel component. Its surfaces exhibit cool elegance and the edge transitions are smooth.
  Back injection molding technology is also convincing as a composition; a material-positive bond across the entire mating surface ensures a durable connection of the parts and also saves on weight. From a production standpoint, there is an advantage because retainers on the underside of components need not be welded on. Instead, these are included in the injection molding process as an inherent feature of the molded part. Finally, automated production ensures full process security.

Radiant surfaces
Because no research work had ever been done for this back injection molded technology, engineers at Scherer & Trier had to pioneer a new frontier. The process begins with a 0.4 mm thick, deep-drawn and contour-true stainless steel preform, to which a bonding agent is applied in advance. The preform is inserted into the injection mold for the molding process and back-injected with plastic. Components are subsequently polished with a stream of glass beads to produce its surface finish.

Collaboration with Porsche has tradition. Even before maturing the techniques for these three Cayman S components, Scherer & Trier had already developed various scuff plates and panels for this sports car manufacturer. Even "little brother" Cayman (where the "S" suffix is missing), which had its debut in June of 2006, is equipped with the same components from Scherer & Trier.


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