3D Imprint - Novel printing and forming techniques for 3D in-mould printing

The needs and issues

3D IMD decoration/printing (3DIMPRINT) for the plastics industry offers production advantages in terms of speed, in relation to the replacement of post-mould finishing and increased durability by under surface printing. The technique involves three separate production processes: printing onto the print carrier substrate, forming the print carrier substrate and the subsequent moulding of the formed print carrier onto a plastic structural substrate. The major problems in the process that inhibit its flexibility relate to issues of forming the print carrier while keeping the print in registration to the ultimate mould.

Techniques for in-mould decoration/printing are limited by thermal deformation of the print carrier during forming which reduces accuracy of final registration of the print as the formed depth increases.

Problems in relation to printing

Existing techniques are limited to: Silk screen printing which although simple and widely employed is time consuming and relatively coarse, and Gravure printing, which is only suitable for mass production having associated high set up costs. There exists a need within the industry for flexible and accurate printing that services the bulk of the market, comprising short-to medium-run products.