Press Information

Georg Kaufmann Formenbau AG
10. May 2010

Technology Day: great interest shown by automotive industry
Muffler-Plastic and Kaufmann give practical demonstration of Varysoft® process

Technology Day visitors watch with interest as sample parts are produced by means of the Varysoft® process on a two-component injection moulding machine. Photo: Muffler-Plastic, Pfullendorf/Germany


The Technology Day was a welcome opportunity for in-depth exchanges of information and opinions between visitors and organizers. Photo: Muffler-Plastic, Pfullendorf/Germany


Varysoft®: soft-touch foam exactly where it is needed
The Varysoft® process developed by Kaufmann permits the single-process production of a moulded part consisting of three different layers: the supporting structure, the foam and the decorative material. The geometry of the back injection mould enables injection of an intermediate layer of foam – either TPE or PUR – of varying thickness in keeping with the degree of comfort required in any one particular area of the part. The back injection moulding process also ensures gentle treatment of the decorative material during the entire processing operation.
For the production of a passenger compartment component, the Varysoft® process permits the injection of a layer of foam (yellow) exactly where it is required in the part and also in the desired thickness for comfort, as the cross-section clearly shows.Illustration: Georg Kaufmann Formenbau AG; Busslingen/Switzerland


Pfullendorf, May 2010. –  On a recent Technology Day, the German firm of Muffler-Plastic GmbH, Pfullendorf, gave around 50 visitors from the automotive industry a practical demonstration of the Varysoft® process developed by the Swiss firm of Georg Kaufmann Formenbau AG, Busslingen. Varysoft® is a process for the back moulding of decorative coverstocks featuring an additional production stage for extra comfort: a layer of soft foam is injected into the space between the supporting structure and the decorative material. The actual thickness of the layer of soft foam in any particular area of the moulded part is determined by the geometry of the mould in accordance with the degree of passenger comfort required.

The sample part produced in the mould used for the demonstration featured the tight radii and complex surface geometry typical of the difficulties encountered in the production of passenger compartment trim. The material for the supporting structure was polypropylene (PP), while the soft foam layer consisted of an expandable thermoplastic elastomer (TPE). The decorative materials used varied between relatively thin TPE sheet, relatively thick TPE sheet and alcantara sheet.

The mould used for the demonstration, built by Kaufmann and equipped with a vertically sliding table, was mounted on a Krauss-Maffei two-component injection moulding machine having a clamping force of 6,500 kN. One injection unit injected the material for the supporting structure (PP), the other injected the expandable TPE. For the purpose of the demonstration, both the placing of the decorative material in the mould and the removal of the finished part from the mould were carried out manually (these operations are performed automatically in mass production). This means that the visitors could observe the individual sequences of the Varysoft® process more easily.

In addition to the practical demonstration, the visitors attended a presentation providing further information on the user benefits of the Varysoft® process and on the possible range of different materials that can be used for the process as well as possible applications outside the automotive industry, e.g. stadium and similar seating systems, or arm and head rests in aeroplanes and train carriages.

Roger Kaufmann, Head of Development and Sales at Kaufmann, sums up the success of the Technology Day as follows: “For us the demonstration of our Varysoft® process was an enormous success and an important further step towards a more intensive development of the market. Visitors from important car manufacturing companies and automotive supply companies could see for themselves how simple the process actually is. We would indeed be delighted if we were able to secure a development contract in the near future on the strength of our Varysoft® presentation.”  Markus Haller, Marketing Manager at Kaufmann, adds: “We have already awakened the interest of an important OEM. We shall now put our heads together and make calculations for a passenger compartment component based on a comparison of the manufacturing costs hitherto and the manufacturing costs using the Varysoft® process. We shall then know for certain what innovation and substitution potential highly integrated Varysoft® technology offers.”

Tobias Muffler, Managing Director of Muffler-Plastic, envisages a definite surge forward in innovative plastics processing thanks to this new development: “We are convinced that the Varysoft® process offers enormous potential when it comes to the development and production of moulded parts for car interiors. And we expect that this technology will really come into its own – slowly but surely – in mass production, initially for relatively small production runs or for special luxury car models. As our skill in the use of the process in mass production increases, we can envisage using Varysoft® parts for all mid-range cars. We also envisage possible applications in commercial vehicles, in the furniture and electrical engineering industries and in the sports and household appliance industries.”

Georg Kaufmann Formenbau AG, Busslingen/Switzerland, specializes in the development of innovative process and mould technologies for the plastics processing industry. These technologies enable the low-cost production of high-quality, highly integrated multifunctional parts. Common to all technologies is the combination of hitherto separate production steps into one single, highly automated production sequence.

Established in 1984, Muffler-Plastic, Pfullendorf/Germany, has been supplying to the automotive industry since 1988. The company operates over 20 injection moulding machines with clamping forces ranging from 400 to 16,000 kN and now specializes in the production of two-component and multi-component moulded parts for car exteriors and interiors. With production and warehousing facilities covering an area of 12,500 m² and a work force of almost 70 employees, the company achieves an annual turnover of around 10 million euros, of which approximately 70% derives from the automotive industry.

Further information:

Roger Kaufmann,  Georg Kaufmann Formenbau AG
Rugghölzli 3,  CH-5453 Busslingen/Switzerland
Phone:  +41 (0) 56/485 65 60,  Fax:  +41 (0) 56/496 54 00
E-Mail:  r.kaufmann(at)

Tobias Muffler,  Muffler-Plastic GmbH,
HesselbĂĽhl 9,  D-88630 Pfullendorf/Germany
Phone:  +49 (0)75 52/93 37-0,  Fax:  +49 (0)75 52/93 37-29
E-Mail:  t.muffler(at)

Editorial contact and voucher copies:
Dr. Diether Burkhardt,  KONSENS Public Relations GmbH & Co. KG,
Hans-Kudlich-StraĂźe 25,  D-64823 GroĂź-Umstadt
Tel.:  +49 (0) 60 78/93 63-0,  Fax:  +49 (0) 60 78/93 63-20
E-Mail:  mail(at)


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