An Ohio company that offers document services is entering the in-mold labeling market with what might be a major technology play. Competitive in-mold offerings generally use identical materials such as polycarbonate label with a polycarbonate part or a polystyrene label with polystyrene part. Compatible melt indexes are critical, creating complications when a plastic is highly filled. “A lot of work goes into matching the like label with a part to insure it bonds well and looks good,” says David Coughlin, director of operations of Industramark, which is being introduced at the National Plastics Exposition this week in Chicago. “This truly is a challenge and a good part of the reason why in-mold labels have not taken off outside of prime labeling applications that are typically only polypropylene.” Working with Fusion Graphics, also of Dayton, OH, Industramark has developed a 7 mil micro porous film. “We do not depend on like chemistries for bonding but rather the plastic (any thermoplastic) being molded flows into the micro bonds and makes a permanent bond to the label. Based on our relationship with Fusion Graphics and their patent position, we have a novel solution that makes other in-mold products obsolete and very complex.”
Labels are not new to Industramark’s parent, Standard Register. They accounted for 13 percent of revenues last year. In response to a question from Design News, Industramark did not provide information on the material used for its in mold labels. A patent awarded to Robert Freund of Waynesville, OH in 2007 describes a new IML technique based on a precipitated silica-filled microporous sheet material. If properly coated, the material is well suited to the IML task, according to the patent. The novel system also requires special inks. The technique is said to not only to improve quality of graphic images, but also to cost less. A wide range of materials, including thermosets, can be used.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
Several new products in this group of new adhesives, coatings, and sealants are formulated to protect sensitive electronic components, or to seal components of commercial and military aircraft. Others are designed to operate in tough, messy, dirty oil & gas operations, or for rotary applications and motors.
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