New Innovative Technology for 3D effects in Injection Molding Plastics
New Innovative Technology for 3D effects in Injection Molding Plastics This paper will discuss the methodology for a new injection molding technique that results in the effect of a 3 dimensional image into a finished part in a one step process.
In the past there have been several ways to decorate plastic injection molded parts.
Mold‐in Color – Where combination of pigments or dyes are used to mass color a plastic part. In‐Mold Labels IML‐‐ In‐mold labeling is a process for labeling a plastic object while the object is being formed in the mold. In the in‐mold labeling process, a label or appliqué is placed in the open mold and held in the desired position by vacuum ports, electrostatic attraction or other appropriate means. The mold closes and molten plastic resin is extruded or injected into the mold where it conforms to the shape of the object. The hot plastic envelopes the label, making it an integral part of the molded object.
In‐Mold Decoration IMD‐‐‐ The term IMD usually refers to decoration of higher value durable plastic products than IML , such as children's toys, sporting goods, automobile dash board bezels, cell phone face plates, etc.
There is a process called over‐molding where one resin is molded over another resin either in 2 stages in the same molding machine at one time or molded at two different times. Parts can be molded and then at a later time placed back into a mold cavity and the 2nd resin/color is molded around the first shape. Over years of testing and developments we know though the reorientation of platelet pigments we can achieve 3‐D effects. In flat printed materials, the finished materials will have the look of heavily embossed paper. This is referred to as Virtual Effect 3 Dimensional printing. In this process the wet ink that contains pearl pigments is pushed with a separate printing plate and then flash dried. The pigment orientation is frozen in the new position and gives a different reflection of light than the ink dried with pearl in a different orientation.
In another molding process, clear resins can be molded over different substrates that have been either printed, stamped or thermoformed and then placed in the mold cavity between each cycle. After the clear resin cools and the mold opens you would have pasts where you can see through the top skin and it could give you a 3‐D look if the substrate has a 3‐d image on it. This new patented technology produces what will be call “Injection Molding 3 dimension effects” in this presentation, and gives the same or similar visual depth to the finished part described above, but, it is all done in a one step process.
Based on the intellectual property of those inventions, the Plastics group began to experiment with the idea of reorienting platelet materials in injection molded parts. To achieve the 3‐D effect
without flow lines, a film containing platelet materials is placed in the mold a method similar to in‐mold labeling placement. In this development we use a flat piece of film with pearl platelet materials in it to be manipulated in the molding process placed behind the clear material. One side of the mold will have the desired image contoured into the surface and the film will be over molded in a clear resin. The completed part with have a deep 3‐D image in each part when viewed though the clear molded skin. The image is created by the platelets being reoriented in the molding process and freezing them in the new position of the desired contoured mold surface.
Key Benefits
Innovative eye catching designs for injection molded parts Use of pearl effect pigments without any unintended flowlines Potential product differentiation with unique 3D imaging effect Increase of brand awareness and recognition
Wide variety of applications and markets
Simple plastic parts suddenly become vivid and multi‐dimensional. References: Patent
EP20140002158 01 / Schum, Markus Laudenauer Strasse 12 64385 Reichelsheim / DE 02 / Linzmeier, Rainer Akazienweg 6 64846 Gross-Zimmern / DE
File date 24.06.2014
In the past there have been several ways to decorate plastic injection molded parts.
Mold‐in Color – Where combination of pigments or dyes are used to mass color a plastic part. In‐Mold Labels IML‐‐ In‐mold labeling is a process for labeling a plastic object while the object is being formed in the mold. In the in‐mold labeling process, a label or appliqué is placed in the open mold and held in the desired position by vacuum ports, electrostatic attraction or other appropriate means. The mold closes and molten plastic resin is extruded or injected into the mold where it conforms to the shape of the object. The hot plastic envelopes the label, making it an integral part of the molded object.
In‐Mold Decoration IMD‐‐‐ The term IMD usually refers to decoration of higher value durable plastic products than IML , such as children's toys, sporting goods, automobile dash board bezels, cell phone face plates, etc.
There is a process called over‐molding where one resin is molded over another resin either in 2 stages in the same molding machine at one time or molded at two different times. Parts can be molded and then at a later time placed back into a mold cavity and the 2nd resin/color is molded around the first shape. Over years of testing and developments we know though the reorientation of platelet pigments we can achieve 3‐D effects. In flat printed materials, the finished materials will have the look of heavily embossed paper. This is referred to as Virtual Effect 3 Dimensional printing. In this process the wet ink that contains pearl pigments is pushed with a separate printing plate and then flash dried. The pigment orientation is frozen in the new position and gives a different reflection of light than the ink dried with pearl in a different orientation.
In another molding process, clear resins can be molded over different substrates that have been either printed, stamped or thermoformed and then placed in the mold cavity between each cycle. After the clear resin cools and the mold opens you would have pasts where you can see through the top skin and it could give you a 3‐D look if the substrate has a 3‐d image on it. This new patented technology produces what will be call “Injection Molding 3 dimension effects” in this presentation, and gives the same or similar visual depth to the finished part described above, but, it is all done in a one step process.
Based on the intellectual property of those inventions, the Plastics group began to experiment with the idea of reorienting platelet materials in injection molded parts. To achieve the 3‐D effect
without flow lines, a film containing platelet materials is placed in the mold a method similar to in‐mold labeling placement. In this development we use a flat piece of film with pearl platelet materials in it to be manipulated in the molding process placed behind the clear material. One side of the mold will have the desired image contoured into the surface and the film will be over molded in a clear resin. The completed part with have a deep 3‐D image in each part when viewed though the clear molded skin. The image is created by the platelets being reoriented in the molding process and freezing them in the new position of the desired contoured mold surface.
Key Benefits
Innovative eye catching designs for injection molded parts Use of pearl effect pigments without any unintended flowlines Potential product differentiation with unique 3D imaging effect Increase of brand awareness and recognition
Wide variety of applications and markets
Simple plastic parts suddenly become vivid and multi‐dimensional. References: Patent
EP20140002158 01 / Schum, Markus Laudenauer Strasse 12 64385 Reichelsheim / DE 02 / Linzmeier, Rainer Akazienweg 6 64846 Gross-Zimmern / DE
File date 24.06.2014
