FIM

This article was supplied by MacDermid Autotype 

Component manufacturers are under greater pressure than ever to produce highly finished products quickly and cost effectively. To enable them to do this, new materials and techniques are needed that are able to deliver consistent results. One such process is Film Insert Moulding, or FIM, which can be used with the latest generation of film substrates to cut costs while improving quality.

FIM enables decorated three dimensional components, ranging from mobile phone handsets to automotive display panels, to be made quickly, simply and cost effectively. As it incorporates fewer stages than conventional methods of component manufacture – simply, printing, forming, trimming, and moulding – the time and cost of making high quality components can be reduced considerably.

In addition to offering a quick and simple method of producing three dimensional components, FIM provides a number of benefits, including the ability to realise complex high definition designs and produce durable textured parts. Components can be shaped extremely accurately and high quality designs achieved that may not be possible with other production methods. Additionally, clear display windows can be incorporated into a single decorated component, reducing materials and costs, while the hard coated substrate used forms a tough protective skin over the surface of the finished part, making it highly resistant to scratches and abrasions.

For the benefits of FIM to be optimised, selecting the right materials, and in particular, a suitable film substrate, is essential. The latest films, such as those in MacDermid Autotype’s Autoflex Xtraform range, combine a scratch and chemical resistant, high gloss surface with the ability to be drawn into complex three dimensional profiles. Films can be chosen that offer varying degrees of workability, from those capable of producing shallow formed fascia panels, to others suitable for deep drawn components such as mobile phone covers. Unlike conventional film substrates, these films can be shaped without the mechanical properties of the film being compromised, resulting in a high quality uniform finish.

With the challenges facing decorated component manufacturers arguably tougher than ever, it is time to look for new ways to combine quality with process efficiency. Using FIM and the latest specifically designed materials, three dimensional components can be produced for a wide range of products, more quickly, simply and cost effectively than ever before.