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INNOVATIVE PRODUCT DESIGN THROUGH FILM INSERT MOULDING
Perhaps as importantly, the latest developments will help to drive down production costs through effective component integration, while introducing greater opportunity for product customisation. Film Insert Moulding is a relatively new production method whereby product designers and manufacturers can considerably reduce the number of stages and processes required to produce component parts for equipment such as mobile phones, PDAs, car dashboard and instrument mouldings and control panels of home appliances. Typically, for a product such as the cover for a personal stereo, FIM can reduce the number of component parts from eleven to just one and the number of process steps from twelve to eight or less. The latest films from Autotype have been developed specifically to meet the demands of the four key process stages in FIM: screen printing, thermoforming, cutting and injection moulding. Autoflex IMD films can be shallow or deep drawn, have a hardcoat surface finish to provide product durability and are optically clear. In addition, they are compatible with the latest IMD screen printing inks and are available with polycarbonate, polyester or PMMA substrate bases. Richard Townsend, Product Manager for FIM Products, explains that, 'Our latest Autoflex IMD materials, combined with new developments in screen inks, offer product designers an exciting range of options. For example, using silver or metallic inks and Autotype Aquatex surface texturing lacquers they can create brushed aluminium and metallic effects for mobile phones at minimal unit cost. Perhaps as importantly, as these effects are produced at the screen print stage, it is possible to customise small numbers of components within a large overall production run.'
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