In-Mold Graphics Molding

In-Mold Painting/Coating

Wilbert Plastic Services has lead the way in the use of In-mold coatings - special paints sprayed onto the mold surfaces - as an alternative to post-mold painting. After application, these paints dry for a brief time so that the injection mixture flows over the semi-dry coating during mold filling. Typically In-Mold painting is used for large, relatively simple parts, without complex details. Other points to consider when selecting an in-mold coating include:

• In-Mold spraying is relatively straightforward and less labor intensive than post-painting.
• In-Mold coating can reduce and, save the cost of, most secondary finishing steps.
• Perfect adhesion between the in-mold coating and the substrate is almost guaranteed.
• Because in-mold systems are low in solids they follow the contours of the mold design very well. Therefore, fine details in the mold will be faithfully reproduced.
• Mold surfaces must be very high quality, as every detail is reproduced.
• In certain instances the presence of an in-mold coating can improve the flow characteristics of the thermoforming material resulting in fewer sub-skin defects.
• Paint usage is relatively low compared with post-painting.

In Mold Decorating

Colors, patterns, wood grains, brushed metal, or bright chrome, plastics in a variety of finishes including glossy, matte, or textured are coming out of molds with every kind of finish and feel. The use of formable films is aiding manufacturers seeking lower-cost and environmentally friendly alternatives to paint and other secondary processes. Already well established in auto interior & exterior trim, and hand-held electronics markets, the appeal of In-Mold Decorating is making itself felt in many new areas.

Formable films are an economical, durable, and environmentally friendly means of producing fully decorated parts right out of the mold. In-mold decoration (IMD) with formable film inserts is replacing traditional post-mold painting, printing, hot stamping, and chrome plating. The process achieved its first successes in modestly sized and relatively flat parts for interior and exterior automotive trim and cell phones. Today, IMD technology has progressed to larger 3D parts such as entire instrument panels, bumpers, fascias, roofs, and even hoods for cars and trucks.

IMD also boasts lower scrap rates, ability to mold and decorate in one location, and improved recyclability. IMD can achieve a Class A surface without the flow marks that can occur with molded-in color.

The IMD or film-insert decorating process starts with a thin plastic sheet that is printed, coated, or pigmented for decorative effect. It is die cut into a blank and thermoformed to the shape of the final part. After being trimmed, it is then placed in an injection cavity, where it is back-molded with a compatible substrate. The surface can be a solid color, metallic appearance, wood grain, symbols and/or graphics.

The leading edge of IMD development is in weatherable Class A finish for exterior automotive and heavy truck applications. Of the six major suppliers of formable films for IMD, five offer outdoor weatherable products and the sixth is working on it.

Contact Us Now!

Request A Quote!