The first layer: thin film
Commonly used materials are PET and PC sheets,and commonly used thicknesses are 0.10mm,0.125mm,0.15mm,0.175mm,and 0.188mm.Because of its excellent molding and processing properties,high surface gloss and good wear resistance,PET is the most widely used.
The second layer: Ink
As the raw material for printing,it needs wear resistance,high temperature resistance,easy deployment and convenient silk screen printing operation.
The third layer: Substrate
Structural Design Requirements:
1.The overall thickness is not less than 1.20mm,the total thickness includes film,ink,substrate.
2.The local glue thickness is not less than 0.80mm,and the place where the glue level changes needs to be inverted bevel transition,to prevent shrinkage marks on the surface of the rubber parts.
3.The diameter of the through hole shall be no less than 1.00mm,the glue width between holes shall be no less than 1.00mm,and the hole shall be no less than 1.20mm from the edge of the rubber shell.
4.The width of the groove is not less than 1.00mm,the rubber width between the groove and the groove is not less than 1.00mm,the groove from the rubber shell edge is not less than 1.20mm.
5.Blind hole depth should not be greater than 0.30mm,and C Angle transition should be inverted.
6.The height of the surface boss is not more than 0.30mm,and it needs to be inverted C Angle transition.
7.All sharp corners and sharp edges on the surface should be rounded at least 0.20mm.
8.The total height of the product is not more than 4.00mm,the total height of the shell and decorative parts is not more than 6.00mm.
9.The side die Angle of the product is not less than 5°.
Process Flow:
1.Raw film:Mostly PET sheets
2.Slicing:The cutting of rolled film into square frames of designed size for printing and molding.
3.Surface treatment: Do special surface treatment,such as vacuum plateing,etc.
4.Plane printing: Make icons and texts that meet the requirements into film nets,and print icons and texts on the cut film square blocks.
5.Ink drying and fixing: Place the printed film square in a high temperature oven to dry,the purpose is to fix the IML ink.
6.Paste the protective film:Avoid scratching the surface of the printed film during the process of punching the positioning hole,sometimes it is necessary to paste a single or double protective film.
7.Punch positioning hole: The thermoformed positioning hole must be punched accurately.The positioning holes in the shearing process are sometimes also punched in advance.
8.Forming: After heating the printed film,use a high-pressure machine or a copper mold to form it in a preheated state.
9.Cut the peripheral shape: Cut off the waste of the formed three-dimensional film.
10. Material injection molding: Put the formed film(Consistent with the three-dimensional shape of the front mold) on the front mold,and inject IML products.
11.Post-processing: Whether to stick a protective film according to the need,etc.
Quality Inspection: Whether the quality inspection meets the design requirements.
