Molding film-insert

Y. W. Leong, M. Kotaki and H. Hamada, Effects of the molecular orientation and crystallization on film-substrate interfacial adhesion in poly(ethylene terephthalate) film-insert moldings, Journal of Applied Polymer Science, 104, 2100-2107... 

Y. W. Leong, U. S. Ishiaku, M. Kotaki and H. Hamada, Interfacial characteristics of film insert molded polycarbonate filmypolycarbonate-acrylonitrile-butadiene-styrene substrate. Part 1 influence of substrate molecular weight and film thickness. Polymer Engineering Science, 46, 1674—1683 (2006). 

The following sections set out the purely materials-related and tool-related prerequisites for the two processes now most commonly used in MID production two-shot molding and laser direct structuring (LDS). Chapter 3 of this book deals in depth with the workflows, possibilities, and boundary conditions associated with these manufacturing processes. It also contains information about the production methods such as hot embossing and film insert molding, neither of which is considered in more detail here from the materials point of view. 

FIGURE 3.22 Diagrammatic view of the process chain for variants of film insert molding (FIM) [48]... 

Primer technology offers a raft of options for structuring three-dimensional interconnect devices. One possibility is to shape silk-screen printed films and then stabilize them by film insert molding (Section 3.1.3.1). Another option is to use tampon printing to transfer a circuit layout directly to a three-dimensional plastic body. 

Film insert molding 100 urn medium simple very high high low - medium high very high... 

In most cases, the injection molding conditions significantly affect the morphology and subsequently the bulk mechanical properties of the product. This effect is more pronounced when polymer blends or composites are used where the extent of dispersion and orientation of the disperse phases or reinforcements would affect the final property of the molding. In film insert moldings, it is important to ensure that the film is firmly attached to the substrate. Hence, the distribution of the disperse phases (Acrylonitrile-butadiene-styrene in polycarbonate) at the interface is investigated to establish correlations between phase anisotropy, film-substrate adhesion and bulk mechanical properties. 

Insert molding, or in-mold decoration, helps overcome the flow lines common to metallic colored intricate injection-molded parts. By this process a film with a uniform orientation is thermoformed and fused with the surface of the injection-molded part. 

Multiple layer film extrusion Thermoforming Film insertion into mold... 

Thin, transparent films of plain PMMA were manufactured using compression molding. The process involves inserting molds between two metallic plates connected to hydraulic pumps and applying pressure and temperature to the raw material placed... 

Three application processes exist for adhering the Dry Paint Film to the part (1) insert molding, (2) in-mold molding, and (3) extrusion lamination. Choosing the right process is primarily a function of part geometry and what elongation the film must endure to cover the part. 

Extrusion Compression Molding with Film Inserts... 

Insert molding, or in-mold processing as it is sometimes known, is characterized by the combination of a printed or structured film with a thermoplastic substrate material. MID technology makes use of this property in a variety of process combinations. 

Y. W. Leong, S. Yamaguchi, M. Mizoguchi, H. Hamada, U. S. Ishiaku T. Tsujii. The Effect of Molding Conditions on Mechanical and Morphological Properties at the Interface of Film Insert Injection Molded Polypropylene- Film/Polypropylene Matrix. Polym. Eng. Sci. In Press (2004). 

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