In Mould Decoration

In Mould Decoration provides an efficient and effective product marking and branding opportunity providing mouldings, off the press, with full graphics and functionality such as unbroken surfaces with living switches and display windows.
Customark as a specialist in product branding is one of the most knowledgeable in the field of In Mould Decoration. Using our print and moulding experience provides unrivalled support for new and existing projects.
The process itself provides tangible process efficiencies and full surface wrap with graphics. The ‘A’ surface of any product can take on the surface property of the films such as Antimicrobial, Hard coat or antiglare. Finished parts off the press without the need for post moulding processing is a significant factor in adopting this technology. The advent of In-Mould structured electronics (IMSE) is the latest development which can incorporate flexible circuits and surface mount components such as LEDs.

MORE INFORMATION

Film insert moulding (FIM)

This is the most basic form of the process and technology is used to decorate moulded components with relatively flat geometry on the face being marked. This process can be used to follow simple 3D profiles such as display lenses. This printed film with deforming and follow a cavity profile with careful mould tool design. The foil can either be placed on pins during the process cycle of the moulding process or simply be placed in a cavity using either a transition fit, static charge or vacuum.

In Mould Decoration (IMD)

This more advanced process requires the printed foil to be formed by Hy.Tech Forming Systems (Euro) Ltd using AccuForm® high pressure forming process. The formed printed sheet is then trimmed to remove excess waste either by hand trimming or matched metal tooling.

Some more advanced mould tooling can ‘nip’ the waste during the moulding process. The subsequent formed and trimmed part is then placed in the mould process cycle. The result of this process can be seen in most automotive vehicles that have ‘back-lit’ switches on their interior controls.
Production of the foil or insert can be printed using a range of methods. Predominantly the high-volume packaging process is printed using an offset litho process and fed automatically during the mould cycle. The more technical projects use screen printing, where the characteristics of the foil or insert are a strategic element of the finished product. Digital printing can be used in some instances where a low volume / full-colour finish is required.
Both processes require the careful use of specialist IMD inks which require post-curing. Failure to understand the nature and performance of the inks will result in gate wash or delamination of the film to the resin or the film to the ink layers.
Gate configuration is important as this can affect the performance of the insert. Shear energy can increase the heat of the resin past the point of ink resilience thus inducing gate wash. Careful processing of the resin pre moulding is very important as moisture content and cavity temperature can have an impact affect both the bond of the insert and the ihV of the moulding.

Below is a graphical representation of the process :


Customark’s process experience allows our customers to benefit from just simple advice to project support to liaising with formers and moulders. Typically, the process requires careful and experienced mould tool design considerations from the start.

Customark’s process experience allows our customers to benefit from just simple advice to project support to liaising with formers and moulders. Typically, the process requires careful and experienced mould tool design considerations from the start.
Customark’s process experience allows our customers to benefit from just simple advice to project support to liaising with formers and moulders. Typically, the process requires careful and experienced mould tool design considerations from the start.
In some instances, mould tools do not require modifications but it is normal for existing process tooling to have some form of adaptation.
Customark work in close strategic partnership with Hy.Tech Forming Systems (Euro) Ltd and technically experienced moulding partners to bring projects to market using specialist film manufacturers such as Bayer, Sabic and Macdermid Autotype. This combined experience reduces costs and lead times for bringing projects to market.

As will all our other services, Customark are always on hand to assist with customers on any new design or existing processes. We would be delighted to offer any support, even it’s just an idea that needs sounding out.

Please don’t hesitate to get in touch with us and speak to one of the UK’s leading In Mould Decoration partners.