LevSurf™: A Technical Evolution in 3D-Formable Hard-Coated Films
- khashayar Ghaffarzadeh
- 1 day ago
- 2 min read
LevSurf™ is a UV‑cured hard-coated polycarbonate (PC) film engineered to enable three-dimensional forming for IMD/FIM manufacturing — combining scratch resistance and robust chemical durability with material flexibility.
The coating is fully cured prior to forming, eliminating the need for post-processing steps like secondary UV curing or lacquer, increasing throughput and reducing defect rates.
Tailored for cover-lens substitution in high-resolution displays (e.g. automotive instrument panels), LevSurf offers optical clarity comparable to glass, with weight savings and potential reductions in CO₂ footprint per vehicle lifecycle.
Constructed using polycarbonate substrate, LevSurf features anti-reflective (F18) or glossy (F04) finishes, each optimized for display readability or aesthetic effect.
The hardcoat layer yields durability — pencil hardness H and full chemical resistance while allowing elongation of up to ~125% during forming without cracking.
The film maintains excellent optical performance, with haze as low as ~0.1% and reflectance around 1.4%, paired with anti-fingerprint and anti-glare finishes for improved visual performance.
Kimoto applies the UV-curable coating using ISO‑certified clean‑room R2R coating lines, ensuring minimal particulate contamination for high-resolution display optics.
After coating, the film can be printed (e.g. for in-mold graphics), then formed via IMD/FIM tooling. As the coating is fully cured, there’s no post-curing required — meaning lower cycle times and higher yield.
LevSurf supports seamless design integration into flowing, curved cockpit surfaces, enabling both functional displays and aesthetic continuity in automotive interiors.
Performance Metrics & Technical Benefits
Hardness: Pencil hardness up to H, delivering abrasion resistance typically reserved for glass surfaces.
Flexibility: Supports elongation up to ~125% during forming operations without delamination or cracking.
Optics: Very low haze (~0.1%) and reflectance (~1.4%) in anti-reflective variants; glossy versions deliver high contrast and gloss perception.
Durability: UV-cured surface resists chemicals and repeated human interaction without requiring protective overcoats.
Applications & Impact
Automotive HMI: LevSurf films are popular for dashboards, infotainment panels, and other high-touch surfaces where curvature and display transparency are essential.
Lightweight display integration: By replacing traditional glass cover lenses, LevSurf reduces weight and contributes to lower production costs and CO₂ emissions.
Large-panel design freedom: Ideal for OEMs and Tier‑1 integrators looking to embed seamless visual continuity across interior trims with multiple display zones.
LevSurf™ represents a compelling fusion of precision materials engineering, high-performance optical coating, and process-compatible flexibility. Its ability to replace fragile glass with lightweight, durable polycarbonate, all while maintaining color fidelity and touch performance, positions it as a disruptive solution for next-gen HMI and display systems in automotive and consumer electronics.
Comments