SPECIALTIES

KEY TECHNOLOGY: IN-MOLD DECORATING (IMD) Via Ink Transfer this is how it works:

KEY TECHNOLOGY: IN-MOLD LABELING (IMl) Via Applique Decorated Sheet Plastic Film Formed or Flat

KEY TECHNOLOGY: IN-MOLD ELECTRONICS (IME) In-Mold Electronics (IME) combines traditional In-Mold Decorating (IMD) technology with Printed Electronics. The result is an aesthetically pleasing, highly-functional, lightweight, and lower-cost alternative to traditional Human Machine Interfaces (HMI) with mechanical switches. In-Mold Electronics (IME) is gaining popularity in the Automotive, Medical Device, and White Goods markets for creation of Smart Surfaces within products. In the near future, other markets will adopt this technology as the advantages and consumer interests are recognized. Typically, an In-Mold Electronics (IME) application starts with the sub-surface screen printing of multiple layers of decorative, conductive, and dielectric inks on sheets of polycarbonate or polyester film. After curing, the printed films are thermo-formed to a 3D shape and die-cut free of the sheet. The imaged thin 3D forms are placed in an injection mold to have clear or colored resin injected behind it. The resulting part is a rigid plastic component with functionality. Surface mount components such as LEDs and connectors can be added prior to or after the forming and molding operations to increase functionality.

Profile Plastics uses multiple precision printing processes to meet your specific demand. Whether you require graphic overlays, durable product markings, simple labels or fully functional printed electronics, we have the capability to meet your need. Our capabilities include: SCREENPRINTING UV curable, solvent based, plastisol and water based inks and coatings are used depending on customer requirement. Special effect inks and surface finishes are used for visual and tactile enhancement of finished product. Conductive and dielectric insulating inks are utilized in our membrane switch and printed electronic products. Print screens are prepared using stainless steel or high tension, low elongation polyester mesh. Stencils systems used include capillary film and liquid emulsion, used stand alone or in combination. Presses include single color clamshell and 4-post, and 6-color carousel with integrated UV curing. DIGITAL PRINTING Profile Plastics has multiple options for digital print including Acuity HS UV cure flatbed, Mimaki LED UV cure flatbed and Roland Eco-Solvent printers. Both Acuity HS and Mimaki UV printers have the capability of full color imaging (CMYK) plus opaque white. The Acuity HS handles substrate up to 48” x 96”, while the Mimaki accommodates material up to 20” x 28”. Our Roland Eco-Solvent printer prints full color (CMYK) plus light cyan and light magenta for extended color range on sheet or roll substrate up to 54” wide. Screenprint and Digital processes can be used in combination, further expanding our product offerings and production flexibility. At Profile Plastics our team understands the importance of precise color matching and color management. A computer-based formulation system, spectrophotometer and transmission densitometer are used to precisely match and control color in our print processes.

The advantages of involving Profile Plastics in your next IMD project: We are dedicated to In-Mold Decorating. IMD is what we do and we do it well. We have 18 years of experience producing IMD products. Our team has more than 75 years of combined experience focusing on IMD. Our experience sets us apart from the rest of the industry. We have developed hundreds of IMD projects. We have developed comprehensive processes for every major market including thousands of part numbers. We offer an in-house automation experience. Our facilities are automated to ensure precision and efficiency in the manufacturing process. We utilize customized IMD manufacturing cells. Profile Plastics produces IMD products in our customized manufacturing cells, reducing throughput, WIP and cost while producing a superior product. Our tooling expertise is developed specifically for IMD. IMD differs from traditional molding in many ways. We understand the details that define the difference. We are ISO 9001 certified. “We will meet or exceed all requirements through our commitment to ISO9001:2008 while continuously working to improve.”

KEY TECHNOLOGY: CELL MANUFACTURING Extensive experience producing product via Form > Cut > Mold Manufacturing Cell Cell Manufacturing Reduces: Costs Lead Times, and Improves Quality 5 Forming Presses Proprietary In-House Forming Process No-Batch Processing Flat Appliques to Formed-In Molds in Minutes Not Weeks In-Line UV Curing Capabilities Dynamic Heating & Cooling (Reduces Molded-In Stress & Weld Lines) Laser Degating