Fomech develop close working relationships with their customer's in the design sector

Customer Case Study:

The Customer

MacDermid Autotype supplies a range of innovative Polycarbonate, Polyester and Acrylic film systems suitable for In Mould Decoration (IMD), allowing you to decorate moulded components.

MacDermid Autotype's mission is to apply technology to help their customers in the electronics, display screen and printing industries to succeed. Their primary focus is on precision coating of films designed to provide scratch and abrasion resistance including the option of producing 3D shapes using the IMD/FIM process.

What is In Mould Decoration / Film Insert Moulding?

In-mould Decoration (IMD), also known as Film Insert Moulding (FIM), is a versatile and cost effective method of decorating and manufacturing durable plastic parts.

Integrate components such as lens, body and keypads into a single component with In Mould Decoration (IMD) formable hard-coated film.

Ideal for telecoms, appliance and interior automotive applications.

How It Works

Film Insert Moulding (FIM) is essentially a specialised form of In Mould Decoration (IMD) that offers particular benefits to designers, processors and manufacturers of a wide range of products.

In essence, the FIM process comprises four stages:
1. The flat film is decorated, the most common method being to reverse screen print the film, thereby protecting the image.
2. The film is formed using pressure or vacuum forming equipment.
3. Each forming is cut to shape.
4. The forming is inserted into a mould cavity, where resin is injected onto the back of the film to create a solid three dimensional object.

The Film Insert Moulding process opens up a wealth of new possibilities for product designers and developers. Compared with traditional methods of product decoration and manufacture, the FIM process offers a number of important benefits:
• Cost Effective
Components parts, such as the lens, body and keypad for a mobile phone, can easily be integrated into a single component. This dramatically reduces tooling and production costs and creates a more robust, higher quality part.
• Durable Long Life Parts
The unique hardcoated films used in FIM offer excellent hardness, abrasion and chemical resistance and, as the film is reverse printed, images are protected from wear or damage.
• Create High Value Lifestyle Products
The advantage of FIM parts is that a common shape can easily be produced with a wide range of different graphics at minimal extra cost, simply by changing the screens used in initial decoration, enabling a standard product to be easily customised in small volumes.

The Challenge

Tim Wright, IMD Business Manager approached Formech with the task of developing a machine to form part of their IMD demonstration facility located at their headquarters in Wantage, Oxon.

A long list of requirements was presented. The following criteria had to be met:
• A high specification machine
• Accurate registration of the printed PC sheet
• Repeatability
• Focus on a machine capable of adapting to both production and R&D
• Economical

The Solution

A visit from the Formech team to the MacDermid Autotype facility in Oxon helped establish the company's precise requirements. With a flexible and cooperative approach Formech were keen to work with Autotype to meet the challenge and in answer to increasing customer demand it was decided to develop a dedicated IMD machine.

The Formech IMD600 is a precision vacuum forming machine ensuring accurate and repeatable registration and forming through the adoption of sophisticated heating and control systems. The machine has integrated devices for accurate registration and a servo-driven table fitted with reference edges to enable repeatability of mould location. The mould platen design will ensure that it locates the mould precisely within 0.1mm in all directions.

The Results

The machine was delivered on time and within budget. Formech's technology has helped MacDermid Autotype realise their vision of a comprehensive IMD test and demonstration centre.

In addition MacDermid Autotype are now able to:
• Use a wide range of PC films and ensure accurate registration and forming
• Produce cost-effective small quantity runs
• Maintain flexibility and control of their designs and not rely on outside vendors

As a result of this cooperation Formech have established an effective working partnership with MacDermid Autotype and actively cooperate together to promote the IMD / FIM process worldwide.

It was very important that we could have a complete FIM solution in place at our demonstration facility – Formech were keen to work with us closely to meet our demanding registration tolerances. We are delighted to continue promoting the benefits of the FIM process with Formech.
Richard Townsend – Product Manager, MacDermid Autotype