Customer Information
2/98 In-Mold Decoration (IMD)
11.02.98
enk/fa
Introduction
Today, most plastic mouldings are first sprayed,
then printed or decorated in a second stage by
the pad or screen printing method, or with la-
bels, transfers, hot stamping foils or hot stamp-
ing transfers.
The idea underlying the IMD process is that
pre-printed films should be placed in the mould
and ‘fused’ directly into the injected plastic com-
pound, resulting in a fully finished moulding.
Conversion from a conventionally decorated
moulding to the IMD process involves rethinking
and redevelopment, making it lengthy, difficult
and, in turn, more costly. However, since many
products today are of identical quality, the IMD
process offers companies an opportunity, in terms
of function and design, to rise above their com-
petitors, with the result that the question of cost is
pushed into the background.
The IMD method affects the manufacturer’s pro-
duction sequence and opportunities open to
designers in the following essential ways:
- Production of printed decorative films is car-
ried out in advance of the actual injection proc-
ess.
- In some cases, the entire printing operation
can be contracted out by the moulding manu-
facturer to specialized printing firms.
- Integrally decorated mouldings reduce costs
by shortening production times, eliminating
intermediate storage and reducing conveying
costs.
- Since the decorative films can be printed flat,
new printing methods such as gravure,
flexographic and screen printing can be used
for mouldings.
- New, 3D effects can be obtained.
- The variety of printing methods which can be
used significantly increases the range of deco-
rative layouts open to designers.
- Designs can be rapidly changed during pro-
duction.
In addition, the feasibility exists for the printed
ink film to be placed between the decorative film
and the injected plastic, thereby increasing the
physical and chemical resistance of the finished
mouldings.
In the light of the numerous statements, advantag-
es and unanswered questions surrounding the
IMD process, a detailed description is given
below.
Contents
1.0 IMD process applications
2.0 Different forms of IMD technology
3.0 Printing ink requirements
4.0 Production process and essential parameters
5.0 Present Marabu status
6.0 Inks available on the IMD market
7.0 Practical tips
Customer Information
1.0 IMD process applications
Today, countless products in everyday use are
already being decorated by the IMD method,
e.g.
Automotive Light switches, window winder in-
dustry: buttons, trims for tachometers,
ashtrays, heater controls and gear
shifts, decorative trims for the
instrument panel and door
claddings, and badges. Materials
used include PC, PMMA, PA, PP,
PE, PS, ABS, etc.
Electrical Radio, hi-fi and television set trims,
industry: switches, rotary controls, shavers,
pocket calculators and mobile
telephones. Materials used include
PC, PA, POM, ABS, PP, PE, PS, etc.
Packaging Fruit juice, yoghurt and cheese
industry: containers, bottle cases and
cosmetics packs. Materials used
include PE, PP, PS, ABS, etc.
Sports Ski bindings, ski boot soles and
goods: training shoe soles. Materials used
are POM, PA.
White Vacuum cleaner on/off switches,
goods: control panels, coffee machines and
irons. Materials used are ABS, PS,
PMMA, PC, POM.
Furniture Garden furniture, all types of
industry: decorated surfaces. Materials are
PP, PE,PA, POM.
2.0 Different forms of IMD
technology
Today, in-mould decoration (IMD) has become a
generic term for a variety of production methods.
They all have one thing in common, namely that
a pattern is printed on a carrier film before the
injection process, which is then incorporated into
the moulding during injection. The following dis-
tinctive characteristics and methods are known.
Printed side 2/98 Page - 2 -
The carrier film can be printed on either side. 11.02.98
Printing on the front is designated as first sur- enk/fa
face printing; printing on the reverse side is
designated as second surface printing.
First surface, single-film system
In this case, the carrier film is printed on the
front and can then (though not necessarily) be
shaped. The printed and possibly shaped car-
rier film is then placed in the mould (or, in the
case of decorative rolls, drawn in by a feeder
mechanism and positioned), after which the
plastic is injected onto the unprinted reverse side
of the film. With first surface printing, the printed
ink film is always on the outside of the plastic
moulding, with the result that all the chemical
and physical resistance characteristics of the
moulding are determined by the type of print-
ing ink used. In technical terms, the first surface
method leaves something to be desired, since
the ink film is positioned on the outside of the
moulding and the expensive carrier film subse-
quently disappears ineffectually in the decora-
tive ink/film combination. Furthermore, it is not
possible to benefit from the advantage of using
different, uniform film textures for the surface
treatment, which must be overlaid with
UV-formulated varnishes. Today, the first surface
method has become a dependable process; it
represents a technical compromise (e.g. FIAT -
heater control trim in the Barcetta) until other
processes achieve a higher level of refinement.
 Customer Information

2/98 Page - 3 - Advantages

11.02.98 - Excellent bonding between the unprinted
enk/fa reverse side of the carrier film and the injected
plastic compound.
- Washing out is impossible, since the carrier
film intervenes.
- Standard ink systems can often be used.

Disadvantages
- The printed ink film is exposed on the outside
of the moulding and is not protected by any
surface film.
- No surface texturing can be achieved with
the carrier film, since this is overprinted with
ink.
- Additional coating with UV-formulated varnish Advantages
or two- component solvent varnish is required. - The printed ink film is protectively positioned on
the reverse side of the carrier film and is thus
First surface, two-film system indestructible.
This is theoretically possible but not used in prac- - The carrier film simultaneously provides the re-
tice. quired surface texture.

Second surface, single-film system Disadvantages

In this case, the carrier film is printed on the re-
verse side and can then (though not necessar-
ily) be shaped. The printed and possibly shaped
carrier film is then placed in the mould (or, in
the case of decorative rolls, drawn in by a feeder
mechanism and positioned), after which the plas-
tic is injected onto the printed reverse side of the
film, partially onto the printed ink film.
Continued presence of carrier film
There are two further methods of second surface
printing, i.e.
a) The carrier film remains on the decorated
moulding
This has a distinct advantage in that the
printed film of ink is embedded between the
carrier film and the injected plastic compound
and is protected by the decorative film. In
addition, the carrier film can accommodate
the desired surface texture.
- Risk of a washing-out spot if the injected plastic
compound impacts the printed ink film.
- Problematical adhesion between the screen
printing ink and injected plastic compound.
b) The carrier film separates from the printed ink
film during injection.
During injection, the printed pattern separates
from the carrier film and becomes attached to
the plastic compound. The now-transparent print-
ing film is drawn out of the mould and rolled
up, and can be recycled or re-used Thus, in this
case, injection is made onto the printed ink film
and the printing ink is positioned on the outside
of the moulding. This method is strongly pro-
moted by the Oeser and Kurz companies and
has achieved widespread market penetration.
Customer Information

- The printed ink film is exposed on the outside 2/98 Page - 4 -

of the decorated moulding and is protected 11.02.98
only by a durable varnish coat. enk/fa
- Long runs of approximately 50,000 mould-
ings and above are needed to ensure profit-
ability.

Second surface, two-film system

Same structure as before but now the printed
reverse side of the film is covered with an
unprinted film, with the result that the injected
plastic compound makes contact with the lat-
ter, instead of the printed ink film.

Ink structure
A transparent polyester film, taken from a roll, is
used as the carrier, which is screen printed or
gravure printed as follows.

1. All-over stripping layer to facilitate separation

of the ink film from the carrier.
2. Two-component, transparent protective varnish,
textured or otherwise. Ultimately, this varnish
is located on the outside of the decorated
moulding, thereby determining its resistance
characteristics.
3. Gravure or screen printed design (1-8 colours). This method was developed and has been pro-
4. Heat sealing varnish providing optimum ad- moted by the Bayer and Proell companies; it is
herence to the plastic compound and protec- better known under the ‘Aquapress’ ink desig-
tion against ink washouts. nation.

Advantages
- Choice of countless standard designs (cata-
logue collection) or new, original design.
- Availability of the experience and expert ad-
vice from Oeser and Kurz for the planning and
production of the entire moulding. Both firms
can also supply the requisite machines and
moulds.
Disadvantages
- Only a limited degree of shaping is possible,
since the flat decorative film is shaped during
the injection process and polyester films can
become creased.
Advantages
- No washing out of ink film, which is protected
by the second unprinted film.
- High processing reliability after running in.
Disadvantages
- Costly, since second PC film required.
- Printing parameters (including atmospheric
humidity) must be extremely precisely moni-
tored, since a water-based varnish is used.
 Customer Information

2/98 Page - 5 - 3.0 Screen printing ink requirements Flexibility: Shaping of printed films before or in
11.02.98 At present, we consider that the printing ink must the injection moulding machine.
enk/fa meet the following requirements: Adherence PC, PS, ABS, PMMA, PC/ PPT. In
to plastics: the adhesion test, an
First surface
average of 20 N/cm is required.
Ink system: Solvent-UV or water based
Heat Between 150 and 290 oC,
Ink range: Complete range of colours plus
resistance: depending on the type of plastic
opaque black and white, varnish
injected.
shades.
Injection Depending on the injected plastic,
Printing Long print runs involved, hence
pressure: film thickness and size of moulding,
capabilities: quick-drying inks, block printing
between 500 and 1200 bar at the
consistency, no tendency to clog
point of injection.
screens, good gradations.
Resistance: Must comply with motor
Opacity: Opaque black and white to ensure
manufacturers’ specifications. The
100% coverage density; coloured
alternating damp heat and climatic
inks to possess customary opacity.
chamber tests deserve mention.
Carrier film: Carrier films are available on the
Fade High quality mouldings, hence good
market made of PC, hard PVC, PS,
resistance: UV resistance required.
PET and PET/PC. Important ink
Recycling: Screen printing ink must not adversely
characteristics are outstanding
affect recycling.
adherence and scratch resistance.
Flexibility: Shaping of printed films before or
In addition, no washing out of the printed ink film
in the injection moulding machine.
must occur during the injection process.
Resistance: Outstanding chemical and physi-
cal resistance characteristics.
Overprinting UV-formulated varnishes or two- 4.0 Production process and essential
capability: component solvent varnishes. parameters
Fade High quality mouldings, hence
resistance: good UV resistance required. Vacuum forming
Recycling: Screen printing ink must not The following standards apply:
adversely affect recycling. - The forming die should be heated to between
40 and 120 oC.
Second surface - Heated, shaped PC films undergo approx.
Ink system: Solvent, UV, or water based 0.5-0.9 % shrinkage during cooling.
Ink range: Complete range of colours plus - Any edges or angles incorporated in the
opaque black and white, varnish moulded part must be rounded, and in any case
shades. by at least the thickness of the printed material.
Printing Long print runs involved, hence - Vacuum deep-drawing dies must not be polished
capabilities: quick-drying inks, block printing smooth; this is to permit trapped air to be
consistency, no tendency to clog expelled.
screens, good gradations. - Vertical sections of material will also dilute the
Opacity: Opaque black and white to ensure thickness of the printed ink layer; beyond a
100% coverage density; coloured certain degree, these become noticeably evi-
inks to possess customary opacity. dent.
Carrier film: Carrier films are available on the
market made of PC, hard PVC, PS,
PET and PET/PC. Important ink
characteristics are outstanding
adherence and scratch resistance.
Customer Information

Injection process 6.0 Present Marabu status 2/98 Page - 6 -

The actual injection process is subject to wide Since every IMD part is subject to different param- 11.02.98
ranging parameters and machine settings. The eters, each enquiry must be considered from scratch. enk/fa
following are of importance; the quality of the As a result, ink types are always recommended on
IMD is permanently affected, depending on set- a case-by-case basis, and then only as the basis for
tings. a series of trials.
First surface
(Data relate to a PC-LEXAN trial at GE, giving We recommend the following combinations of ink
approximate standard parameters) systems and carrier films.
Carrier film PC PC/PET PS PA PP PE
Printing ink SR SR GO PY+H PY+H PY+H
- Temperature at injection point,
GO PY SR SR+H PU+H PU+H
varies according to type of plastic 284 oC PY P+H P+H
- Die temperature, preheated in Printing SRL SRL SRL PYL+H PUL+HPUL+H
machine; can vary 75 oC varnish SRL+H SRL+H SRL+HSRL+H PL+H PL+H
PL+H PYL PL+H PY+H PY+H
- Injection time, can vary 3.6 s
PUL+H PYL+H
- Injection pressure, can vary 800 bar UV- UV- UV-
- Duration of pressure, can vary 6s formul. formul. formul.
- Dwell pressure, can vary 500 bar
- Cooling time, can vary 25 s
- Total cycle time, can vary 40 s Marastar SR is our first recommendation for certain
- Injection nozzle geometry, can vary direct printed materials. If the degree of deformation is
- Injection point, can vary into ink too severe, SR comes up against its limitations. It is
- Number of injection points, can vary 1 also important to verify the adherence of certain
UV-formulated varnishes to SR.

Processing parameters of plastics Second surface

The following data are known to us: To date, approximately 100 different ink formula-
tions have been printed on PC film (GE Lexan 8B35)
and subjected to injection with the following plas-
tics.
Plastic Plastic Temperature Print
colour - PC (GE Lexan 121 or 1110 HF)
PS coloured or approx. 230 °C approx. - PC/ABS (GE Cycoloy)
transparent 700 bar - PC/PPT (GE Xenoy)(PPT is a thermoplastic poly-
PC transparent approx. 285 °C 800- ester)
1200 bar
- ABS 6361
PC/ABS coloured, approx.
e.g. black approx. 260 °C 700 bar - PMMA (Altuglas GR 7)
PC/PPT coloured, approx.
e.g. grey approx. 250 °C 700 bar
ABS coloured, approx.
e.g. black approx. 250 °C 700 bar
PMMA transparent approx. 230 °C approx.
700 bar
PA milky trans-
parent or
coloured approx. 270 °C not known
 Customer Information

2/98 Page - 7 - Standard and newly developed inks have been As with IMD 3060, our own tests with other
11.02.98 tested, with and without accelerators and var- manufacturers’ inks likewise failed to produce
enk/fa nish undercoats and topcoats. The best Marabu perfect results. On the basis of our current knowl-
ink system for the second surface method is spe- edge, there are no IMD inks on the market at
cial ink IMD 3060, so far available to special present which fulfil all the requirements of the
order only. An important requirement is all-over second surface method in every respect. IMD
varnishing with the sealing varnish IMD 3060/ parts produced today are only made possible by
409 49 00. The first mass production parts us- the experience of the firms concerned and the
ing this ink system are now being made. optimization of parameters to achieve an accept-
Carrier film PC PC/PET PS PA able compromise.
Printing ink IMD 3060 IMD 3060 IMD 3060 PY+H
8.0 Practical tips
- The size of the washing-out spot depends on
The problems of adhesion to the plastic, the residual content of solvent in the ink, i.e.
deformability and washing out have not yet been the less solvent there is, the less the amount of
finally resolved, so each IMD part must be proc- ink washing out during the injection process.
essed and tested from scratch. - Thinner printed ink films result in less washing
out. - A heavy coat of sealing varnish reduces
the size of the washing-out spot. We
7.0 Inks available on the IMD market recommend mesh size 49-77T.
Marabu: IMD 3060 1-comp., solvent based - The type and geometry of the injection nozzle
Pröll: Noriphan and 1-comp., solvent based are critical; a directly unobstructed 90o central
Noriphan HTR injection angle is the least favourable. The best
Aqua Press results are obtained with an indirect ‘tunnel’
varnish and 2-comp., water based injection method.
colouredinks - Small parts are easier to process than large.
Nor-Cote: IMD series - A slow flow rate is better than a fast flow rate.
(UV based) UV+solvent varnish - A low injection temperature results in smaller
Coats: HG 1-comp., solvent based washing-out spots.
Colonial: C37 series 1-comp., solvent based - Two-component interlaced ink systems exhibit
Naz-Dar: 9600 series 1-comp., solvent based small washing-out spots but adhere poorly to
Oeser, Kurz: in-house ink plastic and are difficult to shape.
production