To maximise the performance of the Film Insert Moulding (FIM) process, a HMI manufacturer is using formable hard-coated polycarbonate film technology.
IGT Industries, a leading UK manufacturer of man-machine interfaces, has invested in the latest Film insert moulding (FIM) technology, also known as In-Mould Decoration (IMD), as part of its ongoing commitment to providing customers with the highest levels of design and manufacturing capabilities. As part of the investment, IGT is using the latest HiForm formable hard-coated polycarbonate film technology from MacDermid Autotype International to maximise the performance of the FIM process. IGT specialises in the design and manufacture of man machine interface systems including highly sophisticated multi-technology sub-assembly through to PCB based keyboards and passive overlays and labels.
Twelve months ago, the company decided to expand into the relatively new production process of Film Insert Moulding for decorating and manufacturing a wide range of profiled or three dimensional plastic components.
One of the key drivers for expanding into the FIM process was that it offers considerable benefits over conventional methods of component manufacture; in particular, it enables the number of process operations and component parts to be significantly reduced, while improving productivity, quality and the functionality and aesthetics of the finished product.
In addition, the process is highly flexible in terms of design and manufacturing options for shallow and deeply drawn profiles.
This enables original and often innovative design constructs to be considered and can be used to produce both short and long production runs without cost penalties.
IGT has invested heavily in the process in terms of expertise, technology and plant, as Vince Light, Technical Director at IGT Industries explains, 'Having investigated the potential for the process, we believe it is a considerable growth market and with this capability we will soon be able to offer our customers the ability for flexible circuits to be moulded into complex shapes without any loss of functionality or cost penalties.' IGT will be screen printing images using MacDermid Autotype's HiForm substrate for medium draw applications.
HiForm incorporates a unique 'self healing' hard coat on a polycarbonate film base.
The self healing coating gives improved scratch resistance, with the surface gradually healing itself over a period of hours to repair light scratches.
In addition, the film is easily formable by thermoforming or pressure forming, has a gloss finish on both sides of the film and is available in thicknesses ranging from 180 to 750 micron.
Forming is carried out by a specialist partner, Hitech Forming.
HiForm has high levels of transparency so it is possible to reduce component costs by integrating housing and windows in one piece of film through a selective screen printing process.
IGT Industries is already targeting a number of its existing markets such as marine, air and rail transport plus telecommunications, industrial and process control, to promote the benefits of the FIM process.
Vince Light explains, 'Working with world leaders in the field of film insert moulding, such as MacDermid Autotype, enables us to meet our objective of becoming one of the leading manufacturers'.
'We offer high levels of competence in this rapidly emerging technology that provide enhanced quality, functionality and aesthetics for a wide range of finished products.'