Breakthrough! Li Auto’s Large-Scale IMC Component Successfully Rolls Off Line; Wanlong Mold Overcomes 1.4m Extra-Large Molding Challenges
2026-03
Breakthrough:
At 11:18 AM on March 19, 2026, the rollout ceremony for the first large-scale In-Mold Coating (IMC) exterior component was held in Jiaxing, Zhejiang. The event was co-hosted by Li Auto, Fuwei Dongyang, and KraussMaffei, with Wanlong Mould as a key supporting partner.
The successful production of this extra-large IMC part signifies that the industry has officially overcome technical bottlenecks for large, complex exterior components.
Dignitaries including Jiang Ming (Director of Body Dept, Li Auto), Duan Jichao (Director of Materials Technology, Li Auto), Li Hongfei (General Manager of Fuwei Dongyang), and Ren Xinting (General Manager of KraussMaffei China) witnessed this milestone. Mr. Du Xiangwei, General Manager of Wanlong Mould, also attended the ceremony as a core member of the supply chain to celebrate this technical achievement.
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Technical Innovation: Integrated Injection and Coating
IMC technology integrates thermoplastic injection molding and Polyurethane (PUR) coating into a single step within the mold. Compared to traditional processes, this "one-step" method eliminates independent painting and drying stages.
Efficiency & Environment: The process reduces the production workflow by 30%, maintains a scrap rate below 3%, and cuts VOC emissions by 90%.
Quality & Durability: With PUR coating thickness precisely controlled at the 0.1mm level, parts achieve a high-gloss finish, scratch self-healing properties, and superior chemical resistance.
Manufacturing Breakthrough: Cycle time per part is compressed to 120 seconds—30% faster than traditional methods. The integrated manufacturing approach supports rapid capacity expansion without the need for dedicated paint shops.
Cost Advantage: Mass production is expected to reduce overall unit costs by approximately 30%. The investment recovery cycle is shortened as it removes the need for expensive painting lines, requiring only RIM equipment and specialized workstations.
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Overcoming Challenges in Large-Scale IMC Tooling
The project focused on large-scale, complex exterior parts, where the joint R&D team achieved several industry breakthroughs:
Advanced Virtual Analysis: Since no mature system for PUR flow analysis existed in China, the team used SIGMASOFT, MOLDFLOW, and MOLDEX3D for cross-validation. By calibrating virtual models with real-world trial data, a robust PUR coating simulation capability was established.
Extra-Large Size & Complexity: The team successfully developed a 1.4m x 1.2m exterior part featuring continuous steps, openings, and undercuts. To solve substrate deformation issues, Wanlong Mould iterated through four tooling designs, optimizing gate locations and structural reinforcement to keep PUR thickness tolerances within ±$0.1mm.
All-Scenario Sealing Solution: Wanlong designed six distinct mold sealing schemes to cover all typical structures of injection-molded exterior parts, creating the most advanced and comprehensive sealing system in the industry.
Multi-Substrate & Multi-Color: This project marked China’s first successful IMC development on PP substrates, now expanding to PC and PC/ABS. After testing 5,400 samples, the team successfully implemented Transparent, High-Gloss Black, and Metallic Silver PUR colors.
Standardization: The project led to the creation of new design standards for IMC part structures, PP material requirements, and surface quality evaluation criteria for passenger vehicles.
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Jiang Ming, Director of Li Auto’s Body Department, stated that "ultimate products stem from ultimate technical integration," praising the innovation across processes, equipment, and materials.
Wanlong Mould’s breakthroughs in mold structure and precision have not only supported Li Auto’s product goals but have also contributed a solid technical foundation for the high-quality development of China’s automotive exterior industry. Looking ahead, Wanlong Mould will continue to focus on precision R&D and global partnerships to accelerate the industrialization of IMC technology, providing consumers with more aesthetic and eco-friendly mobility solutions.
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