| In-mold Decoration (IMD), also known as Film Insert Molding (FIM), is a versatile and cost effective method of decorating and manufacturing durable plastic parts. The process of in-mold decorating a plastic component consists essentially of 4 stages: Printing, Forming, Cutting and Molding • Printing: The printing operation is used to create the decorative appearance of the product. While a variety of standard technologies can be used for this stage, silk screen printing is most commonly used. • Forming: The forming process converts the flat 2D-printed image into a 3D part which is sometimes referred to as a formed appliqué. This process is sometimes referred to as 'thermo-forming' which is a catchall term to include vacuum forming, hydro forming and high pressure forming. In all three of these techniques, the flat printed image is shaped over or into a tool using negative or positive pressure. The tool can be either male or female, and each type has its own advantages and disadvantages. • Cutting: Cutting of the 3D film may be performed before or after the molding operation depending on a number of factors and usually specified by the IMD supplier. • Molding: The IMD foil(s) is then placed in the cavity of the mold tool and the required resin is injected behind it. The foil can be manually or robotically placed into the tool depending on the volume required and the need for a fast cycle time. The molding process itself will almost certainly have to be optimized to suit the foil. Since all IMD techniques are intended to create cosmetically attractive parts, it will be clear that care in handling of the product is a key issue. |