In Mold Decorating of Injection Molded Parts - Esterline

More documents

Recommendations

Info

In Mold Decorating of Injection Molded PartsIMD offers many design flexibilityand productivity advantages versusother decoration methods done aftermolding. These benefits includedesign flexibility, multiple colorsand effects, textures with a singleoperation, long lasting graphics,manufacturing productivity, andsystems cost reductions.Steps in the IMD ProcessIn-mold Decoration (IMD), also known asFilm Insert Molding (FIM), is a versatile andcost effective method of decorating andmanufacturing durable plastic parts.The process of in-mold decorating a plasticcomponent consists essentially of 4 stages:Printing, Forming, Cutting and MoldingPrinting:The printing operation is used to create thedecorative appearance of the product. While avariety of standard technologies can be used forthis stage, silk screen printing is most commonlyused.Forming:Film is screen printed(decorated) on firstand/or second surface.Film is then formed toshape and cut to finalsize.The forming process converts the flat 2D-printedimage into a 3D part which is sometimesreferred to as a formed appliqué. This process issometimes referred to as ‘thermo-forming’ whichis a catchall term to include vacuum forming,hydro forming and high pressure forming. In allthree of these techniques, the flat printed imageis shaped over or into a tool using negative orpositive pressure. The tool can be either male orfemale, and each type has its own advantagesand disadvantages.Cutting: Cutting of the 3D film may beperformed before or after the molding operationdepending on a number of factors and usuallyspecified by the IMD supplier.Molding:Film is inserted into special moldtool and part is injection molded,permanently bonding decorated film.The IMD foil(s) is then placed in the cavity ofthe mold tool and the required resin is injectedbehind it. The foil can be manually or roboticallyplaced into the tool depending on the volumerequired and the need for a fast cycle time. Themolding process itself will almost certainly haveto be optimized to suit the foil. Since all IMDtechniques are intended to create cosmeticallyattractive parts, it will be clear that care inhandling of the product is a key issue.
Advantages - Disadvantages - ApplicationsOne of the most efficient and cost-effective ways of decorating a part is todo it during the molding cycle. In Mold Decoration (IMD) can provide severalimportant advantages over other decoration methods.Advantages:• Design Flexibility allows customers to expresstheir personalities while the products areeasily manufactured.• Multiple colors, effects and textures with asingle operation that are complete when thepart comes out of the mold.• Legend/graphics wear is almostindestructible with second surface printing.• A cost effective solution over alternativedecorating techniques.• Changing legends / languages / graphics isvery easy by simply changing the printing.Disadvantages:• Time to market issues with necessarydevelopmental iterations.• Some graphics such as concentric circles,long lines and parallel lines should beavoided because of the unavoidabledistortion induced by the IMD process.• Some shape limitations.• Materials are limited to non V-0 rated Polycarbonateand ABS resins.Keytops, Buttons and Key Pads• For scratch/abrasion resistance legends andgraphics.• For multi-color legends and graphics.• For art graphics/decoration• Translucent legends for back lighting.Panels• For scratch/abrasion resistance legends andgraphics.• For art graphics/decoration.• For multi-color legends and graphics.• Integrating components such as a lens /window & a panel.
Page 4 and 5: Common TermsAbrasion Resistance - A
Page 6: Featuring ADVANCED INPUT, MEMTRON,

In Mold Decorating of Injection Molded Parts - Esterline

Create successful ePaper yourself

Delete template?

Save as template?