Paint-free color conference

Automotive Design & Production, Sept, 2004

Solid colors, woodgrains, brushed metal, or bright chrome. Glossy, matte, or textured. In-mold decorating is not just for injection molding anymore--it's moving fast into thermoforming and composites.

Conference Overview, Patrick A. Toensmeier, Program Chairman
8:00-8:10    Why We're Here. Today, plastic parts are coming out of the
             mold with every kind of feel and finish. In-mold decorating
             (IMD) is branching out rapidly as manufacturers seek lower-
             cost and environmentally friendly alternatives to paint or
             other post-mold decorating. Another one of these
             altematives is molded-in "special effects" colors that
             mimic metallic paint or provide looks that even paint can't
             match. (10 min.)

In-Mold Decorating: Injection Molding
8:10-8:45    Introduction to Applications: Why IMD is Hot and Where It's
             Happening
             SPEAKER: Patrick Griffin, Bayer Corp. (30 min)
             Already established in auto interior trim and hand-held
             electronics, the new frontiers for IMD are large automotive
             parts and home appliances. (5 min. Q & A)
8:45-10:10   PANEL DISCUSSION: The Available Spectrum of IMD Films
             SPEAKERS: Mike Kozbial, Avery Dennison; Patrick Griffin,
             Bayer Corp; Robert O. Johnson, GE Advanced Materials; Bob
             Travis, In-Mold Graph Graphic Solutions; Tim Hoefer, Mayco
             Plastics; John Cupstid, Soliant (10 min. each)
             IMD can utilize dry-paint films, coextruded films, and
             printed films. Speakers will discuss the capabilities of
             each type, their current applications and future potential.
             (25 min. Q & A)

10:10-10:30 COFFEE BREAK

10:30-10:55  Ins & Outs of Printed IMD Inserts
             SPEAKER: Michael Terlizzi, Serigraph (20 min.)
             Woodgrains and registered graphics or labels for in-mold
             application require several steps: screen or offset
             printing, die-cutting, forming, and back molding. Careful
             selection must be made of film material, inks and first- or
             second-surface printing to match the application. (5 min. Q
             & A)
10:55-12:20  PANEL DISCUSSION: Equipment for IMD
             SPEAKERS: Norton Kaplan, Automated Assemblies; Helmut
             Eckardt, Battenfeld; Horst Schmidt, Build-A-Mold; Joseph
             Portelli, Fanuc Robotics; Paul Gelardi, E Media/Hekuma;
             Rick Shaffer, Netstal; David Preusse, Wittmann (10 min.
             each)
             Hear the experts tell what it takes in injection machines,
             robotics, and tooling to make IMD work. (20 min. Q & A)

Luncheon Discussion in Conference Room
12:20-1:45   What's Next: In-Mold Painting SPEAKER: Jason Forgash, UBE
             Machinery
             If you have to use paint, why not do it in the mold? The
             technology is already here. (20 min., including Q & A)
             In-Mold Hard Coating of Multi-Cavity Parts SPEAKER: Hermann
             Plank, The Tech Group
             New technology using a rotating stack mold applies a clear
             hard coat to optical parts. (20 min., including Q & A)
             Complimentary lunch served concurrently.

In-Mold Decorating: Thick-Sheet Forming (TSF)
2:00-2:45    Introduction to Process and Applications
             SPEAKERS: John Montagna, Durakon; Jeff Zawacki, Hendrickson
             (15 min. each)
             Decorative films are laminated to sheet and thermoformed
             into parts that come out of the mold fully finished. Truck
             bumpers, front fascias, running boards, stone guards,
             rocker molders are already commercial. 15 min. Q & A)
2:45-3:30    PANEL DISCUSSION: Equipment for Thick-Sheet Forming
             SPEAKERS: Albert Woltron, Geiss; John Brumitt, AVT (15 min.
             each)
             Leam about the types of thermoforming equipment that are
             best suited to this application. (15 min. Q & A)

3:30-3:50 COFFEE BREAK

Special-Effects Pigmentation
3:50-5:10    Role of Special-Effects Coloring in Today's Market
             SPEAKERS: Patrick Griffin, Bayer Corp.; Robert B. Johnson,
             GE Advanced Materials; Jean Sirois, Clariant Masterbatches
             (10 min. each)
             Color and appearance are becoming more important to
             marketers as a means of product differentiation and
             consumer appeal. What's trendy in special effects today?
             (15 min. Q & A)
5:10-5:30    PANEL DISCUSSION: Processing Techniques for Special
             Effects
             SPEAKERS: Patrick Griffin, Bayer Corp.; Robert B. Johnson,
             GE Advanced Materials; Jean Sirois, Clariant Masterbatches
             (10 min. each)
             Tips from the experts on achieving the best results with
             metallic-effect and other special colorant systems in
             molding and extrusion. (15 min. Q & A)