What are the Basics of In-Mold Decoration

Insert-Mold or In-Mold Decoration (IMD) also known as Film Insert Molding (FIM) is the process of inserting a printed graphic overlay into an injection mold. The molding process entraps the overlay or film in a plastic, thereby assimilating the advantages of functional and decorative graphics with a plastic molded assembly or component.
In-molding decorating allows decoration of parts during the molding phase thus eliminating the need for post-processing. Consequently, this leads to greater design flexibility; overall system cost reductions, and enhanced manufacturing productivity.

Components of In-Mold Decorating

In-mold decoration eliminates traditional post-molding decoration techniques as multiple colors of durable graphics can be injected into the plastic components. Because the graphics parts are integrated into the resin, it is impossible to remove them without destroying the particular part with in-mold decoration.

Parts are complete with in-mold decoration. The graphics remain vibrant and won’t fade and one can modify the printed overlay if there is an update required. There is normally no need for updating the mold. The three main in mold options where in-mold decoration can be applied include lenses and windows, dead front graphics and back-lit graphics.

The in-mold Process

The main component of the in-mold process is a polycarbonate film. Graphics are typically printed on the inner surface (second surface) of the film. And on the outer surface of the film texture of a selective gloss is printed. The second surface printing offers extra protection to the last application. Decoration s then done to form the film which is then trimmed and put in the mold. The last step involves injecting the molding.

Design Considerations in the In-Mold Process

There are certain considerations made when the mold is being designed. One of these is placing the graphics in a relatively flat area far from sharp edges. This helps in limiting registration and distortion. To prevent any wash out in the gate area of the components, specific inks are usually used. Gates are also put in the furthest distance to the graphics that can be possibly achieved, which helps in reducing the turbulent flow of material during the molding cycle.

Increasing Efficiency In In-mold Decoration

Injection molders who prefer decals or labels for their decoration as opposed to the traditional post molding can increase the efficiency I decorating using two ways.
The first method you can use is to buy purchase labels that are on a roll and die. You then need to cut these at the press prior to loading them into the tool. This calls for some experience and knowledge in die cutting, knife-sharpening schedules, and installation of bulky equipment by the press.

The other option is to purchase pre-cut labels in stacks which you then load into nests or fixtures to be delivered robotically to the mold. This option comes with its own unique challenges, for instance, you need to treat the labels with an antistatic solution to prevent them from sticking onto each other. Static problems occur with humidity changes, which mean you should be able and ready to find a solution within the shortest time possible.

Conclusion:

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