TECHNOLOGY | SURFACES
Above: An example of the FIM process is a system built around an Arburg hybrid Allrounder 630 H for the production of several variants of interactive, flexible 3D displays for washing machines
ics and white goods, as well as medical and packaging technology. In addition to high-quality machine technology in a clean production environ- ment, a smooth production process requires the economical use of materials and processes, a flexible manufacturing process with the integration of upstream and downstream production steps, and a high level of traceability and reproducibility. Alongside processes such as FIM, the focus in future will also be on more in-depth automation and digitalisation of processes, says Arburg. IMD is used to transfer designs and colours from a continuous film, which is automatically fed into the mould cavity, to the components. In the IMD process, the films are transported into the mould from a reel via a feed unit on the closing system’s fixed or moving mould mounting platen. A special sensor system is used to connect to the machine controller, while precise positioning is achieved using optical sensors. This allows large batch sizes to be produced economically in series. The main application of IMD is in the automotive and electronics industries. In contrast, IML is mostly used in the packaging
industry. In this process, thin insert films or labels are automatically inserted into the mould cavities and in-mould laminated with plastic. The firm connection between film and plastic is achieved by the injection process. Short cycle times can be achieved by using multiple moulds and simultane- ous insertion and removal. The parts can be used without any finishing, and a downstream part inspection is possible.
FIM also involves in-mould lamination, although in this case, film preforms are used. Due to particle deposits, the films must be cleaned before insertion.
14 INJECTION WORLD | October 2021
This can be done with brushes or ionised air. The inserts are usually positioned using vacuum grip- pers, since the pickup can take place at an uncritical point and the gripper can be positioned precisely in relation to the mould. The mould cavities are cleaned simultaneously with removal using brushes and ionised air. In this area, Arburg adds that it provides technical solutions that can be connected to a cleanroom or operate as a fully integrated part of a cleanroom. In addition to the automotive and electronics industries, medical technology is also a growing FIM segment. FIM can be used to produce interactive displays and ‘intelligent’ surfaces, for example. Touch films of this kind have mainly been used on flat surfaces to date, but they can also be realised in 3D for curved components. Arburg highlights an example of the FIM
process in a system built around a hybrid Allround- er 630 H with 2,500 kN clamping force and cleanroom module for the production of several variants of interactive, flexible 3D displays for washing machines. This results in completely new product and design possibilities. The parts are produced in two mould cavities. The PolyTC film with metal mesh structures is electrically conduc- tive and enables cost-effective production. The injection moulding machine works docked to a cleanroom, in which all upstream and downstream steps take place to prevent electrostatic charging and contamination of the films and components. The entire handling is performed by a six-axis robot. The finished parts are checked downstream for their electrical function, among other things, in various processing, testing and laser stations. Two pre-treated films are each then bonded to the moulded panels in an automated process. The sprue is separated in the laser station. The touch panels are finalised and visually inspected for quality in the operating area and packed for overseas transport. The serial production of injection moulded parts with structured surfaces is another process where development has been significantly boosted by the automotive industry, adds Arburg. There are many possibilities for creating structures in the mould that go as far as achieving a 3D-like appearance. The process involves the targeted modification of the surface’s look and feel, combining textures with 3D effects and leather, carbon, or even high-gloss finishes. The design is almost unlimited in terms of component geometry. With regard to mould design, the use of suitable mould steels, the accessibility of the mould cavities with the laser required for structuring, the material removal, and the ratio of grain depth to tapering contours to
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IMAGE: ARBURG
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