Appliance Design - September 2007 - (Page 57) DECORATION Appliance control panel with graphics applied by film-insert-molding. components are then cut to size before being moved to the final, injection-molding stage. Each part is subsequently inserted in a female injection mold cavity, where molten polymer is injected behind the film to form a strong and create a solid and finished part ready for subsequent product assembly. This simple but effective combination of processes delivers a number of important benefits, including the ability to realize complex high-definition designs and produce durable, textured parts. In particular, as the components can be shaped extremely accurately, with print registration within +/- 0.2 mm, high quality designs can be achieved that may not be possible with alternative production methods. In addition, for products such as appliance control panels, it is possible to integrate a decorated enclosure and clear LCD display window into a single component, reducing the materials required and, therefore, costs. Furthermore, by printing the decoration or graphics onto the undersurface of the film, the hard coated substrate forms a tough protective skin over the complete outer of the finished part. This makes each component considerably more resistant to scratches and abrasions than those that have been sprayed or have had designs applied to them. In many respects, the success of the FIM technique has only been made possible by the availability of a new generation of performance films and inks, that are capable of withstanding the different mechanical and thermal stresses encountered at each stage of the overall production process. For example, the latest film substrates, such as those in the Autoflex Xtraform range from MacDermid Autotype, feature a specially developed, high-gloss, hard-coated surface finish and have been developed to offer a combination of properties. These include www.applianceDESIGN.com the ability to accept intricate graphics and a range of inks; to be shaped using pressure, heat or vacuum forming systems; and to provide resistance to surface abrasion, physical wear and chemicals, greases and solvents. In addition, they have excellent resistance to ultra-violet light, so they can be used for extended periods in sunlight; offer high levels of transparency, so that backlighting can easily be incorporated; and can be surface embossed or textured. Perhaps most importantly, the films have been specially developed to offer consistent results when drawn into three-dimensional shapes using FIM techniques. The range of films offer varying degrees of workability, from those capable of producing shallow formed fascia panels, to others suitable for deep drawn components such as instrument covers. Unlike conventional film substrates, these films are able to be shaped without weaknesses occurring or the mechanical properties of the film being compromised, resulting in a high quality, uniform finish. Additionally, the inks used for the FIM process should be chosen carefully, as conventional screen print inks are not generally formulated to withstand the higher temperatures and mechanical stresses imposed during thermoforming and injection molding. Many specialty inks are now available, while products such as Aquatex texturing lacquers from MacDermid Autotype have been developed to enable a variety of tactile finishes to be applied to the surface of products formed using FIM techniques. One of the main advantages of FIM is its ability to reduce production costs when compared with traditional techniques, with savings of up to 40 percent being possible in many applications, mainly through reductions in processing times and the labor required. For more Information Enter 137 applianceDESIGN AD09074Craft2.indd 1 September 2007 57 8/8/07 1:59:04 PM http://craftoriginators.com http://www.appliancedesign.com
For optimal viewing of this digital publication, please enable JavaScript and then refresh the page. If you would like to try to load the digital publication without using Flash Player detection, please click here.