Back-Molded Foils

Process for the in-mold lamination (IML) of decorative foils by way of back injection molding. This process has been optimized to achieve a high level of precision and is capable of molding tight radii (minimum 0.6 mm (0.023 in). There is no delamination and adhesion problems as there would be with alternate processes that employ adhesives to adhere the materials to already molded parts. The foil is screen printed, thermoformed (for 3D parts), die-cut, and back injection-molded with polymers such as polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). The foil has a typical thickness of 0.25 mm (9.8 mil); minimum thickness of molded parts are 1.5 mm (59 mil); maximum injected weight of molded parts 170 g (6 oz). The foil can be printed to imitate materials such as aluminium or wood grain, or printed with geometric patterns. A combination of matte and gloss effects can be printed, as well as soft touch finishes; a thermochromic foil is also available. Applications include consumer electronics and interior automotive trim.