Appliance Design - September 2007 - (Page 58) Terrapin G DECORATION Automotive audio electronics panel decorated by filminsert-molding. Nano-Hardcoated Plastic Films Terrapin G beats conventional hardcoats hands-down in resistance to scratching, abrasion and chemicals. Durability Flexibility Optical Clarity Advanced Terrapin G Hardcoated Films from Tekra are perfect for demanding opto-electronic lens and appliance applications. PDA and cell phone windows, touch panels and displays, signature verification devices, and decorative nameplates are but a few possibilities. Best of all, this “film of tomorrow“ is available today from Tekra, in polyester or polycarbonate. Terrapin G 2006 PRODUCT OF THE YEAR SGIA Membrane Switch Symposium Contact us now to discuss your application! 800-448-3572 www.tekra.com © 2007 Tekra Corporation For example, on a product such as the outer case for a personal CD player there may be up to 11 different components, including etched metal labels, metallized buttons and molded case and display area, with about 12 separate production processes (spray painting and hard coat, pad printing, screen printing, etching, etc.) being involved. By switching to FIM, it is possible to reduce the number of component parts to just one, with only eight production processes being required (including printing, forming, die-cutting and injection molding), representing a considerable saving in both production costs and time. Similarly, for parts such as instrument or control panels on business machines, medical equipment or industrial systems, FIM techniques will both reduce costs, when compared with spray painting, and dramatically improve the durability of text and graphics, as they are sealed beneath the surface layers. In addition, the ability to create extremely fine print definition makes FIM an effective method of simulating wood or carbon fiber effects, while the use of special varnishes, overprinted during the first stage of production, enable textured and gloss finishes to be selectively created around or on control knobs or switches. Although FIM represents a major step forward for the production of high quality components, there are a number of important factors that should be considered at both the product design and production stages. Perhaps most importantly, it is essential to recognize that FIM is essentially an integrated procedure and that it can involve a number of different suppliers and processes. Typically, these can include raw material (film, ink and resin) suppliers, screen printers, forming or injection molding companies, and, of course, the OEM or end user. It is important that all of these parties are consulted and that agreement is reached on the integration of each process step, with careful consideration being given to the affect that each step may have on preceding or subsequent stages. For example, film materials and inks must be formulated to match the often diverse characteristics of both screen printing and subsequent forming and injection molding processes, without suffering from problems such as ink washout, melt damage, or degradation of material properties. Additionally, the production of highvolume parts, such as fascia panels for white goods, can easily be achieved at the screen print stage, as multiple images can be printed on each sheet of film or using roll-fed machines. However, a production bottleneck may subsequently occur at the forming stage, as high-precision thermoforming systems are only generally capable of handling smaller numbers of units per production cycle, making careful planning of the overall process a necessity. It should also be noted that most films used for FIM have been designed for that purpose and are extremely resilient, enabling both shallow and deeply drawn shapes, typically up to 3.0 cm in depth, to be produced without surface cracking or affecting their mechanical or physical properties. In choosing the best films it is, however, important to consider the requirements of the final application so that, for example, chemical or abrasion resistance is incorporated. Similarly, there is a growing range of screen printing inks that have been developed specifically for FIM and these are able to withstand the high temperatures and shear stresses imposed during injection molding. Bear in mind, however, that the inks lay between the film and the molten resin so can easily be damaged by heat if they have not www.applianceDESIGN.com For more Information Enter 138 58 applianceDESIGN AD03074TEK.indd 1 September 2007 1/31/07 9:10:02 AM http://www.tekra.com http://www.appliancedesign.com
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