Film Insert Molding for Automotive Exteriors

Contract manufacturing for decorative plastic molded products for automotive exteriors
skid plates, pillars, EV front grilles, and more

Benefits of film insert molding for automotive exterior components

Manufacturing process with low environmental impact

Film insert molding is a method in which decorating is carried out at the same time as injection molding. The film insert molding manufacturing process is extremely simple, partly because no drying processes are required. As a result, film insert molding can reduce CO₂ emissions from the fabrication process by about 50% compared with exterior-resin decoration through painting.

Realization of diverse designs

With film insert molding, various designs can be realized that cannot be achieved through painting.
The possible designs include metallic finishes, carbon-fiber patterns, and geometric designs; furthermore, on the back surface of molded products, film insert molding makes it possible to achieve hidden-until-lit (dead-front) designs that incorporate LED light sources.
Through our in-house CMF Design Team, we at Nissha propose high-quality designs while listening to customers’ requests—please first let us know what you would like to do for your film insert molding program.

Carbon pattern

Hair line

Metallic color

Abstract pattern

Translucent light emittion
(Dead front)

Geometric pattern

Durability equivalent to that of painted products

In film insert molding, the top layer uses specially processed acrylic films to provide outstanding chipping resistance. Furthermore, film insert molded products meet the durability specifications required for exterior components, including resistance to weather, chemicals, and other exposures.

Incorporation of functional components such as heaters

With film insert molding, we have developed technologies that enable the incorporation of electronic components into plastic molded products. Our manufacturing solutions—useful for ADAS development—include methods for embedding wire heaters into molded parts and for integrating LEDs into the molded surface.

Radio-wave transparency

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Touch screen
embedding

Heater embedding

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IR-wave transparency

Large-scale film injection molding

We operate injection molding machines up to the 850-ton class, enabling film insert molding of large automotive exterior components. Typical parts include bumper guards, door/roof trims, and pillar appliqués, and our production lines support the full flow for film insert molding—from preforming and trimming to back-injection—so large parts can achieve paint-less, Class-A surfaces at scale.

Film insert molding case by Nissha contract manufacturing

Front panel with wire heater for electric vehicle (EV)

This front panel, produced by film insert molding, integrates a paint-less decorated surface with an embedded wire heater to prevent snow accretion on the vehicle’s LiDAR sensor area. The heater structure is designed with radio-wave transparency in mind so that sensor performance is not affected.

Embedded heater on Backside of the molded panel

Film insert molding applications by Nissha contract manufacturing

Film insert molding can be applied to a wide range of automotive exterior parts. Typical film insert molded applications include B-pillar appliqués, side door garnish/moldings, mirror caps and other exterior design components, and bumper skid plates. For each part, we review geometry, edge treatment, and validation targets to define the optimal film insert molding stack and process—ensuring consistent appearance and exterior-grade durability across film insert molded components.

Technical information regarding film insert molding

Fabrication process

Printing

We are able to accommodate the process for film insert molding starting from the printing of decorative films. Using multicolor gravure printing machines, we can create not only monochrome expressions, but also a diverse range of patterns that are achieved through the overprinting of various inks for film insert molding.

Film preforming

The films that have undergone printing are preformed through pressure forming. For the decorative films, olefin or acrylic films, which have outstanding stretchability, are used so they can follow deep shapes required in film insert molding, such as bumper guards and center-cap ornaments.

Film trimming

Following the preforming, the unnecessary portions of the film are trimmed in accordance with the size of the molded product, using a Thomson cutter or laser processing machine, preparing the film for film insert molding.

Film insert molding

The trimmed film is inserted into a mold, and insert molding is carried out. During this film insert molding step, the film is integrated with olefin resin—frequently used for exterior components—through the thermal pressure of injection molding.

We possess an integrated mass-production process that ranges from film printing in Japan to film insert molding overseas. As a result of this, we are able to supply film insert molded products globally. Also, we can accommodate supplying just films to a designated molding factory according to customers’ requests.

Film composition

Top layer

For film insert molding, this consists of acrylic films that meet exterior specifications.

Decorative layer

In film insert molding, we create diverse designs by gravure printing, screen printing, vapor deposition, and more. We can propose designs per customer requests, including carbon-fiber patterns, hairline finishes, and metallic finishes.

Backer layer

For film insert molding, this consists of olefin films focused on adhesion to the molding resins.

Molding resins

We can accommodate general molding resins used for exterior components—such as TPO and PP—for film insert molding.

Nissha business models with supply chain

Film roll delivery

Film insert molding film roll delivery is possible for those who mold in house—we supply printed and pre-formed decorative films ready for film insert molding at your facility.

Molded parts delivery

We can supply film insert molded parts from Nissha’s global factories.
We can process film insert molding at your preferred location worldwide.

Nissha global sites for film insert molding

Nissha has molding bases around the world, allowing production to provide parts near our customers and supporting film insert molding programs. Where required, sites can handle film printing, preforming, trimming, and film insert molding to suit regional production needs.

We can provide service that starts with addressing customer’s questions and concerns

We are able to accommodate requests that include:
• Requests to see films for film insert molding
• Requests to view film insert molded samples
• Requests to receive prototypes for film insert molding based on your drawings

We would like to encourage customers to first of all consult us about your film insert molding program.