Advanced Thermoforming, 2nd Edition

Chapter 17Deco Molding and Multi‐deco Molding

Written in Cooperation with Klaus Wlasak and Marcus Schuck, Jacob Plastics GmbH, Wilhelmsdorf, Germany

Deco molding is a special technology consisting of primary forming processes, for example, thermoforming and injection molding, to create unique formed parts. The objective is to create surfaces that are highly decorated and pleasing to the eye for component parts with extreme 3D shapes and almost limitless geometry. Through the forming of the film even complex geometries with decorations can be implemented to the rear side of the component parts (edge folding). A typical process combines the forming of a film in order to create an insert, as well as the following cut in order to obtain the final contour by means of a separate working process with the injection molding process. So‐called inserts, which are three‐dimensionally formed, are inserted into the injection molding tool and processed with back‐injection molding. The semifinished product is a film that is formed by means of the thermoforming process, printed, and subsequently cut to the desired dimensions. The three‐dimensionally formed semifinished part with the final contour is called an insert. The injection molding process must guarantee the adaptation of the film to a basic part, for example, a car dashboard. The back‐injection molded material represents the material connection to the insert, which guarantees a rigid structure and a positive fitting or force‐fitting ...