Simultaneous Injection-Decoration System IMD/IML

IMD/ IML (Simultaneous injection-decoration system)

IMD ( In Mold Decoration )

IMD = In Mold Decoration is the technology to apply versatile CMF finish onto 3D geometry plastic surface during injection molding.
This technology widely used in consumer electronics, appliance, automotive and medical/healthcare devices, and supports customer to achieve unique CMF finish on mechanical parts with high quality and productivity.

Key benefits

Hard coat protection

Hard coat protection

Nissha’s UV cured hard coat layer protect surface against scratch, chemical, UV irradiation without secondary process.

3Decoration on 3D geometry

3Decoration on 3D geometry

Since decoration is applied at the same time of injection molding process, surface decoration follow 3D geometry.

Precise registration

Precise registration

Nissha foil feeding system contorlled by optical sensor enables precise registration within+/-0.25mm.

High productivity by roll to roll system

High productivity by roll to roll system

Film printing and IMD molding is managed by roll to roll system. Its production is automated and efficient.

Environmental friendly

Environmental friendly

Thin IML ink is only applied to the area where decoration is needed. Volatile organic compounds can be reduced.

work well with capacitive touch sensor

work well with capacitive touch sensor

NISSHA’s IMD works well with capacitive touch sensor, no harm on its sensitivity

Process

Composition

Composition

IMD is a simple and productive process. Decoration is done inside of the tooling without any pre / secondary process, and the whole process is controlled by a roll to roll system. Decoration is completed, including hard coat protection, with just a single shot molding.

Process Flow

Gravure printing

Gravure printing

IMD film is printed by high speed gravure printing process.
7 layers of graphic color (max) plus also hard coat layer and adhesion layer are applied during this printing process.

IMD molding

IMD molding

A foil feeder is installed on the injection machine. IMD film is then fed between the injection molding tool. Optical sensors in the feeder adjust registration of the film, and the ink printed on the film is transferred onto the plastic by the heat and pressure of injection molding.

Product

Product

After injection molding, you have complete decorated products. No secondary process is necessary. (only UV curing for hard coat)

Versatility of CMF design

Depth / Multi layer effect

Depth / Multi layer effect

Hidden til lit

Hidden til lit

Brushed Hair Line

Brushed Hair Line

Gradation

Gradation

Marble stone

Marble stone

Wood grain

Wood grain

Leather

Leather

Fabric texture

Fabric texture

IML ( In Mold Labeling )

IML = In Mold Labeling is the technology to apply printed and pre-formed film onto 3D geometry plastic surface where film and plastic are merged (mixed?, adhered?) during injection molding.
This technology is especially suitable for decorating deep and complex shape. Furthermore, because of surface IML film layer, a high-quality exterior with a sense of depth and robust physical properties are available.

Key benefits

Complex curved geometry available

Complex curved geometry available

Dedicated forming process prior to injection molding forms IML film deep draw and complicated geometry.

IML film layer protection

IML film layer protection

Graphic layer is fully protected from abrasion by IML film. Additional functionalities like UV or chemical resistance is available by special films.

Environmental friendly

Environmental friendly

Thin IML ink is only applied to the area where decoration is needed. Volatile organic compounds can be reduced.

Production lot flexibility

Production lot flexibility

Nissha range of printing methods allows flexible manufacturing. Silk-screen printing for lower volume production, Gravure printing for higher volume production.

環境にやさしい製品

Versatile surface finish

Unique coating and printing technology can create excellent natural finishes including tactile texture, effects like stainless steel, natural wood, and fabric-like patterns.

Process

Composition

Composition

IML process consists of multiple steps – printing, forming, trimming and molding.
Because of the dedicated forming process, IML process is well suited for deeper draw parts and complicated geometries.
Also, since the carrier film remains on the surface with the IML process, a high-quality exterior with excellent physical properties and a sense of depth can be achieved.

Process Flow

Printing

Printing

For IML film, Nissha has two printing methods – Gravure printing and Silk screen printing. Depending on design specification and production volume, the best printing method is chosen.

Forming and Trimming

Forming and Trimming

IML film is set in the forming machine and formed into the geometry of the part’s shape by high heat or high pressure. Then the periphery film is trimmed by die cut machine or laser.

IML molding

IML molding

Formed IML film is inserted into the injection molding tool and combined with resin.

Product

Product

After injection molding, the result is finished decorated products.

IMD/ IML comparison

IMD IML
Layer structure Layer structure Layer structure
Film Released Remain
Remain Roll to Roll Sheet
Process Simple (Just Molding) Multiple (Forming / Trimming / Molding)
Geometry Shallow Flexible (Sharp, Deep)
Volume Middle – High volume Low – Middle volume

Design example

Design example

Inquiry

Please feel free to contact us.

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