101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS

101 processes to
1. Blending
Blending of different polymers can
decorate or be used to create new effects, such
as improved barrier properties to
and using the moulding process
itself to deform the sheet (see In-
mould forming). Bayer have
recently extended the process to
enable antennas to be integrated

surface treat
gas, aroma, or liquid permeation.
Eastman, for example, have
recently developed various polymer
plastic blends for improved barrier in
relation to PET.
with plastic components. Akzo-
Nobel Soliant produce metallised
films that avoid the need for
separate metallizing. Ju Teng have
developed a process for using a

components
Ed Crutchley
Crutchley Consulting
May 2012
Keywords: Decoration, surface
treatment, functional, aesthetic,
plastics, in-mould, pre-treatment,
coating, metallizing, printing.
decorating, assembly.
Processes
Raw materials modifications
In-mould
Treatment
Organic coating
Printing and decoration
Inorganic coating
Assembly
Introduction
The range of processes to decorate
or aesthetically change plastic
surfaces in manufacturing is vast.
Solutions vary from in-mould
operations to contact and non-
contact processes and various
forms of vacuum deposition. In this
article we list 101 of the main
processes. See also our article
entitled 101 Functional or
Decorative Effects on Plastic
Components’ .
This article lists some of the
most commonly encountered.
Some examples of recent
developments are provided. For
more details on those, refer to the
3D Plastics Decoration and Surface
Treatment Annual Innovation
Review, details from
www.crutchleyconsulting.com.
Raw materials modifications
rotating mould in order to
2. Internal additives simultaneously trim and form and
Additives can be blended with a back-mould. Other suppliers
polymer in order to produce a wide continue to improve films and
range of effects. Nano-composites materials for the FIM process, and
can alter scratch resistance or DSM offer a one-step process for
barrier. Slip additives provide in-mould applying a pre-printed
lubrication. Antistatic additives also thermoplastic elastomer to a
migrate to the polymer surface in moulded surface.
order to make it conductive so as to
allow dissipation of static charge. 6. In-mould assembly (IMA)
Additives from Milliken clarify Components are assembled during
polypropylene. the moulding cycle using parts
produced in rotating or stack
3. Pigments moulds. A good summary on the
Pigments provide coloration and subject and information on
also special effects and are the companies active in the field can be
subject of constant innovation. New found at Plastics Technology On
effect pigments have recently been Line (link).
developed by companies such as
BASF, Merck, Silberline, JDSU, 7. In-mould coating
and many others, and final This normally refers to a process
products by Polyone, EMS, whereby a low-viscosity polymer or
Novartis, and others. reactive material is injected over a
moulded component after the
mould has receded enough to allow
In-mould processes space for feeding.
The process has mainly
4. Bi-injection developed with a number of patent
The injection of a second material applications since 2000, and
either in the same cycle or in a two- particularly since 2008, with
stage process allows for numerous demonstrations at plastics
decorative effects. The top material exhibitions. Engel have developed
can, for example, be translucent in their Clearmelt process and
order to provide a depth look. KraussMaffei their Clear Coat
New applications have been Moulding (CCM), ColorForm,
developed by Toyo Seikan, CoverForm, SkinForm processes.
Flextronics and others. PU or acrylates are examples of
coating. Coating suppliers include
5. Film insert moulding (FIM) Bayer and Evonik (Plexiglass CF).
This process was developed by
Bayer and has found use in the 8. In-mould decorating (IMD)
automobile industry. It is relatively The most common in-mould
expensive by virtue of the need to decoration process is hot foil
pre-print a flat sheet of, for stamping, possible on relatively flat
example, polycarbonate, high- surfaces. The mould is designed to
pressure form, trim, and then place allow a reel-fed foil to be fed
the moulding into a mould cavity through so that polymer will be
for back-moulding. injected against the foil, thereby
Recently attempts by Cie forming a bond with the décor.
Automotive and others have been Kurz, one of the main players,
made to simplify the process by have recently developed a
trimming in the injection mould technique for moulding both sides
of a foil, and another, Nissha, for a

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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
process where a component is
decorated both sides at once. Dai
Nippon have developed a device
which reduces cycle time and foil
usage.
The process can be used to
transfer a film that replaces spray
coating.
9. In-mould flocking
This process refers to inserting a
flocked film into the mould prior to
injecting. Companies providing this
process are Lextra and FiberLock.
10. In-mould foaming
Blowing agents can be used to
expand plastics in order to produce
a tactile effect. Plastic corks are
manufactured in blown EVA.
11. In-mould forming (IMF)
See also Film Insert Moulding
(FIM). The closing of a mould is
used to deform a film to the shape
of the component. This process is
used in order to decorate or protect
a plastic component.
BASF have recently developed a
method for a temporary protective
layer that is removed after
moulding.
12. In-mould hold pressure (IMHP)
This process has recently been
developed by Dupont in order to
improve surface quality and cycle
time of thick-walled components in
semi-crystalline materials (PE, PP,
PBT and PET).
13. In-mould labelling (IML)
In-mould labelling is widely used in
food packaging. It avoids the need
to separately decorate a 3D object.
The printed label is either fed from
web and cut inline or is pre-cut and
fed directly from hoppers, posing
the label inside the mould cavity
while barely affecting the machine
cycle time. The label is held in
place inside the cavity by vacuum.
This process is only suitable for
relatively simple shapes, such as
flat surfaces, cylinders, or slight
cones.
As well as high quality
decoration, the label can also
provide other properties such as
barrier to permeation (see recent
developments by Alcan Packaging
Beauty and Innovia films), anti-
fingerprint protection, etc. There
are many IML label producers,
such as Verstraete, Helioplast,
CCL Label, Stratus Packaging,
Mondi. Among equipment
suppliers are Machines Pages,
Hekuma, Marbach, Ilsemann, Beck
Automation, and many others.
Dai Nippon have developed a
solution for reducing label shift
during the injection phase. Krones
have recently developed a high-
speed in-mould labelling process
for a blow moulding operation.
Sarong have developed a labelling
process to be employed in
thermoforming.
14. In-mould lamination
A sheet is bonded to a component
during the moulding process.
BASF have developed a film
with a removable layer so that the
surface is protected during
moulding. International
Automotive Components have
developed a process to create a
depth of image effect by
sequentially back-moulding and
front moulding a printed appliqué.
15. In-mould metallizing
This patent-applied for process (see
JP 2004338328, Oshima Denki
Seiskusho) has been developed for
automobile headlights, whereby a
die-slide mould (see JSW) is used
in order to internally deposit a
sputtered metallic film in a
vacuum.
16. In-mould painting (IMP)
Liquid or powder coatings are
sprayed onto the cavity surface
prior to injection. The major
application of this process has been
for automobile dashboards.
Gram have developed a process
that employs a rotating mould to
electrostatically spray paint into a
cavity and then UV cure.
17. In-mould surface patterning
Etching the cavity surface either
with an image or a texture such as
Charmilles. The technique is also
used in non-decorative nano-
patterning for medical and
electronic uses.
18. In-mould roller (IMR)
IMR is similar to IMD except that
the backing film is removed after
moulding.
SiPix have recently developed
an easy-to-clean film for IMR.
Etansi Inc. have developed an IMR
process for replacing spray coating.
19. In-mould welding
Two surfaces can be moulded in an
injection moulding cycle. See, for
example, the Engel JoinMelt
process www.engelglobal.com.
20. Insert moulding
An appliqué or decorative metallic
part can be pre-placed into a mould
prior to injection.
Rexam have developed a
process for integrating a RFID tag
into a moulded bottle. Research in
Motion have developed a process
for embedding metal components
in a plastic moulding.
21. Marbleizing
A second screw on an injection
moulding machine introduces a
separate colour just before the
injection nozzle so as to
deliberately reduce mixing in order
to obtain a non-homogeneous
blend in the final product.
22. Multilayer injection or
extrusion-blow moulding
Multilayer moulding using multiple
extruders and special dies allows
the possibility of including internal
permeation barrier layers as well as
the disposal of regrind. The process
is also capable of producing
decorative effects.
Improved methods and
materials for multilayer moulding
have recently been proposed by
Ulrich Stieler, Kraft Foods, BASF,
Graham Packaging, Kortec, EMS
and others.
Netsal, Glaroform and Ilsemann
have developed a multilayer
container solution that integrates
an aluminium foil, and Kortec have
developed a hot-fillable PP
container.
23. Rapid heat cycle moulding
(RHCM)
Component surface quality can be
improved by heating the cavity
surface temperature. Rapid cooling
must be then used so as not to
penalise cycle time. Many different
processes exist for heating,
including the use of induction (see
RocTool), steam, and resistance
heating.
Aperam and Arcelomittal have
recently developed induction
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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS

solutions in tools, and new Carbon dioxide ‘snow’ is projected Deionising must always be
solutions have been proposed by onto component surfaces in a carried out prior to any operation
Mitsubishi Heavy Industries and highly effective process used for intended to remove dust form a
Nada Innovation. cleaning of electronic components, surface by blowing or brushing, as
and also on some spray coating the electrostatic forces can cause
lines. This is a process that involves dust to remain adhered to the
Treatment processes the use of carbon dioxide surface.
recuperated from industrial Equipment is supplied by
These are designed to ensure processes and supplied by companies such as Simco-Ion,
cleaning, surface preparation, and companies such as Messer and Haug, Meech, Elcowa, Eltex, and
adhesion prior to any deposition Linde. Since applied at high others. Polonium 210 has also been
process and/or otherwise alter the pressure it is noisy and raw used to achieve the same result.
surface of a material. material costs have to be
considered. The cleaning quality 31. Electron beam irradiation
24. Atmospheric plasma treatment can be impressive, and is used by E-beam irradiation has been used
At atmospheric pressure the Volkswagen among others (process to increase the hardness of PA66
electrode must be placed within a developed by ACP-Micron). and other plastic materials.
few millimetres of the plastic US patent 7901540B2 for Dense
surface in order to provide effective fluid cleaning provides for a 32. Flame treatment
treatment. This process is therefore cleaning and adhesion improving Flame treatment is a well-
only suitable for relatively flat or process involving carbon dioxide established method for ensuring
concentric surfaces, but is highly snow and active species which is adhesion of inks and coatings
effective for light cleaning and projected against a component particularly to polyolefin surfaces
increasing surface tension through surface. and is still widely used because of
oxidation. It is used to pre-treat on Ergonomy LLC have developed its effectiveness and flexibility. PE
decorating and spray coating an improved process incorporating and PP surfaces are inert and have
machines. propane into carbon dioxide. low surface tension (about 30-32
Plasmatreat have extended their dynes/cm). Flame treatment (or
process in order to treat the inside 28. Chemical etching corona or plasma) cleans and
of components such as tubes. Chemicals, such sulphochromic oxidizes the surface and raises the
Improved plasma devices have acid, are used to treat a plastic surface tension, which must be at
recently been developed by surface in order to assure adhesion, least 36-40 dynes/com for good
Reinhausen and Leibniz-Institute particularly for electroplating. adhesion. The cleaning capacity of
among others. BASF have flame treatment is limited;
developed a process for plasma 29. Corona treatment significant amounts of oil, grease,
treating painted films in order to Corona treatment is commonly or migrated additives will not be
alter properties or improve used on films to improve adhesion, removed effectively, and treatment
adhesion of a topcoat. and has also been extensively used level will be reduced. Flame
Plasma can also be used to for treating blow moulded bottles treatment is not considered
etch/ablate plastic surfaces. and extruded tubes. An electrode is effective for removing dust, but it is
placed within a few millimetres of employed for removing flash and
25. Brushing the polyolefin surface to be treated. tails after injection moulding.
Dust particles under 20 microns are The electrode either contains an Among many companies
difficult to remove with adjacent earth or the electric supplying equipment are Flynn
compressed air alone, and discharge passes though the plastic Burner and Arcotec.
mechanical means are needed. to a ground the other side.
Brushes are usually made of robust 33. Glow discharge treatment
but soft naturally antistatic animal 30. Deionising This is carried out under low-
hairs (camel, goat, horse, etc), Static charge remains on most pressure, at around 10-2 mbar.
except where longer lengths are plastic component surfaces by Components are subjected to a
required, in which case modified virtue of their low electrical high voltage discharge for several
nylons are used. Ostrich feathers conductivity that prevents charge minutes in order to oxidize and to
are preferred by the automobile dissipation. The charge is initiated some extent clean a polyolefin
industry. Brushes are supplied by by any number of actions such as surface, although this could not be
companies such as Mink Beursten, rubbing, handling with suction considered a highly effective
Todd Thin Brushes, and Kullen. cups, removing from a mould or cleaning process.
form packaging. In most cases, the
26. Burnishing charge on plastics is negative. 34. Ion-beam treatment
A surface is pressed for example Deionising involves blowing See the paper entitled Super Hard
with a metallic tool or tumble with ionised air onto parts so as to Surfaced Polymers, Mansur et al.
ball-bearing in order to smooth it. neutralise the charge, and the (www.sampe.org).
effectiveness can be assessed either Hyundai have recently
27. Carbon dioxide cleaning with a digital meter or by a dust developed a process for improving
pickup test. gloss and scratch resistance of PP,

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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS

thereby avoiding the need for 40. Static removal Where components require an all-
coating. See Deionisation. out organic coating and are difficult
to hold, dip coating is often used,
35. Laser etching 41. Ultrasonic aqueous degreasing for example on lenses. The process
Lasers are used to etch a surface in Aqueous degreasing is also used on has also been used as an alternative
order to remove polymer. plastics, and found increased for spraying, one example being for
favour when regulations were basecoats and topcoats for vacuum
36. Low-pressure plasma tightened for the use of solvents. metallizing model Eifel Towers.
treatment Parts can be sprayed, but the usual Coatings must have low viscosity,
This is analogous to Glow method is to immerse them and use and therefore contain high levels of
discharge treatment. Different ultrasonics in order to remove solvents, and component removal
gases (oxygen, nitrogen, argon, etc) grease and particulate. A technique is critical so as to avoid
can be used in order to influence degreasing line consists of multiple tears on the last portion to be
the chemical nature of the treated rinsing operations in order to removed. Various techniques are
surface in order to tailor-make its remove cleaning products. used in order to reduce this effect.
suitability for specific coating One challenge in immersion Essilor have recently developed
chemistries. techniques is to avoid parts a process for rotating a lens in
floating. Usually plastic parts are order to even out coating thickness.
37. Polishing degreased in bulk, although this
A surface is dry or wet polished in increases the risk of scuffing. 46. Drum coating
order to improve gloss. This can be (see Handbook for Critical Small components can be tumbled
carried out in a vibratory bowl Cleaning for a thorough treatment together in order to be coated. This
using bulk media, or by using of the subject). is the normal process, for example
mechanically driven polishing for coating pills. For painting, small
heads. 42. UV-photografting plastic components are tumbled in
Chemicals such as benzophenone a warm rotating barrel while a fast-
38. Sandblasting are sprayed or otherwise deposited evaporating paint is gently sprayed
Sandblasting has often been used onto, for example, a PE or PP into the chamber. The paint dries
in order to provide a satin or matte surface in the presence of UV light upon contact. This process
feel to a plastic surface. However, in order to modify the surface for produces a matte effect ideal for
this process provides a surface adhesion. door handles and pens.
susceptible to scuffing and Equipment suppliers are
scratching, and in recent years Specialty Coatings and Walter
matte coating has been preferred. Organic coating Trowal.
A well-known supplier for
sandblasting is Guyson. Beneq Oy 43. Atmospheric plasma deposition 47. Dry paint film application
have recently developed a refined See Atmospheric plasma treatment A pre-coated film is adhered to the
sandblasting process for in the Treatment section. Plasma component surface. This avoids a
controlling surface structure. can also be used to deposit organic spraying operation, but is suitable
materials onto plastics, for example only for flat substrates.
39. Solvent vapour or immersion for superhydrophobic or anti- Karl Woerwag Lack-und
degreasing bacterial effects. A suitable Farbenfabrik have recently
Solvent degreasing is generally precursor is introduced into the developed a process by which a
recognised as one of the most plasma stream. tack-free dry paint film is applied to
effective methods of cleaning a a substrate coated with adhesive
plastic surface. In the past, Freon 44. Curtain coating prior to curing.
was extensively used until the 1977 Liquid coating is poured over a
Montreal Protocol resulted in its surface and runs off the side to be 48. Electrostatic spraying
abandonment. Nowadays, many recuperated and recycled. This If components can be grounded,
different solvents are used (see process is used for coating flat electrostatic spraying can allow
Handbook for Critical Cleaning for panels or objects such as skis, and considerable savings in coating
a thorough treatment of the can be used to replace spray consumption. There are several
subject). In vapour degreasing, coating, for example for clearcoats types of electrostatic applicators,
solvent vapour is allowed to or basecoats and topcoats for including pneumatic guns, discs,
condensate on the plastic surface. vacuum metallizing. The process and bells. Bells are the most
In immersion degreasing, involves large amounts of solvent. commonly used, the tip spins at
ultrasonics are used in order to Ricoh have recently developed a around 40,000 rpm to produce a
dislodge grease or particulate nozzle for blowing off excess fine mist. The absence of
matter. These processes take place coating from the edges of a curtain- compressed air to atomise means
either on slow moving conveyors coated panel. that the mist does not shoot past
(<3.3 metres/min) so as to avoid components, and coupled with
solvent carry-through, or in totally 45. Dip coating using electrostatics, transfer
enclosed systems. efficiency on plastic components
can be more than doubled.

4
 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
Grounding of the plastic
component can be achieved by
applying an all-over conductive
primer that allows grounding
through the part holder.
Conductive plastics for this process
continue to be a subject of
innovation. Already, without
resorting to the above solutions, the
presence of a grounded metallic
part inside the component, as part
of the holder, can produce
significant effects.
Ransburg have recently
developed improved spray pattern
controls for an electrostatic bell,
and US20110159169A1 proposes
improved temperature control of
shaping air. Conductive plastic
blends for electrostatic spraying
have recently been proposed by
Govern General International, and
Princeton University.
49. Flocking
Flocking involves spraying,
dipping, or printing an adhesive
onto the plastic component and
then running it through a flock
cloud of prior to curing.
An equipment supplier is Maag.
50. Flow coating
See Curtain coating.
51. Inkjet spraying
Inkjet technology can be used to
apply coatings. The much shorter
distances involved result in very
high transfer efficiency and
reduced cleaning costs, but flow
rates are more limited.
Phillips have recently developed
the Vuecoat process for applying
hard-coats onto plastic surfaces. A
recent patent application
(US20110262622A1) claims
simplification of a spray booth for
automobile components due to
inkjet-type spray heads being used
instead of conventional spraying.
Mankiewicz have claimed a patent
for using inkjet process for coating.
52. Kinetic cold gas spraying
Non-melted powders are
accelerated in supersonic gas jets
and adhere to the surface after
impact.
MTU Aero Engines GMBH have
recently developed this process for
coating plastic surfaces.
53. Low pressure plasma
deposition
See Low pressure plasma
deposition in the Inorganic
deposition section. Low pressure
allows more parts to be treated at
greater distance, and overall
coverage is also better. Organic
precursors are used.
54. Laser cladding
Laser cladding involves exposing a
powder applied to a plastic surface.
See Fraunhofer (link).
VITO (NL) have developed a
process for improving the adhesion
of powder laser-clad to a plastic
surface.
55. Needle or pin transfer coating
Needle coating has been used
primarily to deposit an array of
points of adhesive onto a surface.
3M have recently developed a
continuous needle coating process
for spirally coating cylindrical
components.
56. Parylene deposition
Parylene is an inert barrier material and sometimes additional UV-light.
with an oxygen permeability about However, due to particle size, film
the same as PET. It has found use
as a water barrier for electronic
components and to protect
documents requiring preservation.
The normal manner to apply this
material is under low pressure,
whereby the material is evaporated a coating capable of curing at 800C.
and deposited onto surfaces inside
the chamber at up to 5 microns per ultrasonic process for levelling out
hour.
Aixtron have developed a
process that reduces substrate
heating during parylene deposition. rate, penetration and film
An atmospheric deposition
processes has recently been
developed by Osram.
57. Pneumatic spraying
Pneumatic spraying is the standard
method of painting plastic
components. Low-viscosity coating
material is fed under pressure to
the gun nozzle (either gravity-fed,
pressurized, or via mechanical or
peristaltic pumps). Compressed air
applied to the nozzle provokes
atomisation into a fine mist. The
higher the pressure, the finer the
atomisation, but also the greater
the amount of ‘overspray’. For this
reason high-volume, low-pressure
(HVLP) or low-volume, low-
pressure (LVLP) and various other
techniques have been developed in
order to improve transfer efficiency
without sacrificing deposition
quality. When properly carried out,
a spray-coated surface can have the
finest quality of all types of organic
coating. In mass production,
spraying is carried out with parts
loaded onto pin conveyors, for
example chain-on-edge, so that the
conveyor is placed below the parts.
Some variants of spraying
processes for special effects are (1)
splatter coating, where atomizing is
deliberately reduced so that large
coating particles are projected onto
the component, (2) ‘wet-look’,
where the second coat contains
large amounts of silicone which
cause it to bead up, and (3) string
coating, where fast solvents
evaporate before the paint lands on
the component.
58. Powder coating
Powder coating typically involves
electrostatically spraying powder
instead of a liquid coating. The film
is then melted and cured using heat
thickness tends to be high,
sometimes leading to unsightly
edges, and curing temperatures
required (>1200C) are too high for
most common plastic materials.
Dupont have recently developed
They have also developed an
powder prior to curing. Akzo Nobel
have developed a fluidized bed
process in order to improve coating
uniformity, and a two-coat dry-on-
dry process not requiring
intermediate curing.
59. Spin coating
Round flat surfaces, such as lenses
or DVD’s, can be coated by
spinning. A drop of liquid coating
(which may be a UV-curable
coating without solvents) is applied
at the centre, and the component
spun at high speed in order to
centrifuge the coating into a thin
film.
Spin coating materials and
equipment are provided by a
number of companies including
Lenstech. Tokyo Electron have
recently developed a process for
5
 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
applying the coating material by
capillary force prior to spinning.
60. Supersonic thermal spray
NGimat have recently developed a
process for PC using nanoparticles
for improving the durability of
super-hydrophobic surface.
61. Ultrasonic spraying
Ultrasonic energy can be used to
atomise a low-viscosity fluid
emerging from a narrow bore.
Spray delivery rates are limited, so
several heads may be required in
order to increase output in a
production system. Atomized
particle size tends to be larger than
that from electrostatic bells or
pneumatic spray guns, and
therefore the process has found
used primarily for coatings with a
high amount of dilution. The
transfer efficiency is very high by
virtue of the fact that particles a
larger and spray jet is relatively
slow, and equipment using such
spray technique remains
remarkably clean.
This technique find uses in
medical and electronic fields (test
tube coating and circuit board
protection). See Sono-Tek.
Fundacio Privada have
developed an ultrasonic device for
selectively spraying molten plastic
material.
Printing and decoration
62. Doming
This technique is widely used for
protecting badges and has been
used for decorating the tops of
caps. Viscous epoxy or
polyurethane clear resin is applied
to a component using a syringe so
as to produce a dome. There is a
3D decorative value in the final
result.
63. Dry offset printing
This process can be used on flat or
cylindrical objects at speeds of up
to several hundred components per
minute. Paste ink is applied to a
hard relief printing plate which in
turn transfers to a rubber blanket
that transfers under pressure to the
component. Most printing is multi-
colour, employing several printing
stations transferring onto the same
blanket, and inks are dried and relief die, so the process can also
cured by on-mandrel or inline be used to apply a protective
using UV curing. The use of a coating to a component, thus
single blanket implies that inks avoiding the need to spray.
must be tack graded. Foils are produced by
The process is often used to companies such as Kurz, Nissha,
print bands around cylindrical ITW and others. Due to plate costs,
components, and a recent patent the process is best suited to longer
application talks of improving runs or to replace decoration
overlap quality by using a halftone operations where more than 2
in the overlap area. Key players in colours have to be sequentially
this field are Polytype, Van Dam, printed on separate machines.
OMSO, Montoli, and others.
67. Hot foil stamping
64. Embossing A thin polyester carrier foil is
A relief metal plate is pressed coated and often metallized. A
against the component surface, release coating melts under heat
usually under heat, so as to leave a and allows image transfer to a soft
relief image in its surface. With substrate. An integral topcoat
plastic materials an intermediate protects metallisation or the
film is sometimes used in order to pigmented layer in order to provide
avoid molten plastic build-up on adequate resistance properties of
the plate. Sometimes the process is the final print. The foil is applied to
combined with hot foil stamping. a component using a heated
Kurz have recently developed a silicone or metallic relief die. The
high speed embossing machine for process is sensitive to 0.02mm
curved surfaces. changes in component thickness,
and therefore moulding and core-
65. Flexographic printing centring must be accurate
This process can be used on flat or CER have developed a hot foil
cylindrical objects at speeds of up stamping machine for peripheral
to several hundred components per marking of conical objects. Hot
minute. Low-viscosity ink is applied stamping on glass and hard
to a rubber relief printing plate materials has recently been
which in turn prints the facilitated by Verreries du Courval
component. An offset version also who have developed a machine for
exists in order to address applying a basecoat inline with foil
components which are stamping and subsequently UV
dimensionally less accurate. Most curing the basecoat. The same
printing is multi-colour, and company have developed a flexible
therefore involves printing on hot silicone pad for decorating
multi-station machines, and inks complex shapes.
are dried and cured by on-mandrel
or inline using UV curing. The
process is pressure sensitive to 68. Inkjet printing
0.02mm changes in substrate Ink is dispensed from an array of
thickness. piezoelectric nozzles. The process
OMSO have recently developed is digitally controlled, so one image
an indirect flexographic process for can be different to the next, and
cylindrical or conical plastic can be quite fast. Inks can be UV-
components. Various companies cured. The process is non-contact,
have recently proposed wet-on-wet and substrate distance can vary
solutions, thereby avoiding the several mm without affecting print
need to dry and cure the substrate quality.
after each colour application. Whereas high-quality printing
onto flat substrates using X-Y
66. Heat transfer printing plotters and with on-board UV-
A process close to hot foil stamping curing has been developed by many
in which the carrier foil is pre- companies such as Mimaki,
printed with an image. The image Roland, Agfa, and many others,
has to be registered to the decorating 3D components is still
component to be decorated. at early stages. Solutions have been
Transfer is assured using an all-out recently proposed by Mimaki, Hon
flat silicone die as opposed to a Hai, Plastipak, Volker Till and
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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
KHS, Inkcups, Pad Printing of
Vermont, Dubuit and others.
Dai Nippon have developed a
control system for locally adjusting
print quality on the fly. When
substrates are moving at faster
speeds, pollution from ink misting
can become a problem, and several
companies have developed mist
capture devices.
69. Labelling
A label is applied to a component.
ITW have recently developed a
high-speed labelling process from
web for contoured bottles, and
Avery Dennison a flexible pad
process for ensuring that labels are
applied without wrinkling or
bubbling. See also Sleeving.
70. Laser marking or etching
A laser is used either to etch or
discolour a component surface.
Sometimes special colour-changing
pigments are incorporated into the
plastic component or in a coating
pre-applied to the component. One
interest in the process is that
substrate distance is non-critical.
Hamano and Samsung have
recently developed processes for
selectively laser etching a
metallised component. Improved
laser marking additives for plastics
or coatings have been recently
developed by DSM, Merck, and
BASF. Datalase have developed a
process for multi-colour laser
printing using distinct wavelengths
and different colour-change
additives. Macsa ID and Philips
Electronics have developed
accelerated laser marking
processes for high speed
production.
Antolin Grupo have recently
developed a laser process for
selectively removing flock.
71. Magnetic pigment orientation
In a process patented by Tefal in
1968, flaked metallic pigments can
be made magnetically sensitive.
When inks or coatings containing
such pigments are subjected to low
to medium-strength magnets prior
to drying, varying pigment
orientation created by patterned
magnets produces interesting
depth-look effects. The process has
also found uses in security printing.
In spray coating, magnets are
either placed within 1-2 mm above
the paint surface or in the
component holder. Coatings
contain slower solvents in order to
allow time for the orientation
process.
72. Nameplates
Nameplates are often flat or
contoured decorated metallic
objects that confirm with and are
bonded to a component surface.
73. Pad printing
An etched plate with an image is
filled with low-viscosity ink and
excess ink removed with a blade. A
soft silicone pad picks up the ink
and transfers it to a component
surface in rotary or flat mode.
During the transfer the inks dries
on the silicone surface, and
therefore acquires enough tack to
be almost fully transferred. This
process is ideal for decorating
complex surfaces. Film thickness is
low, and so sometimes a ‘double
hit’ is required in order to opacify
the decoration on a contrasting
surface.
Shuhou have recently developed
a ‘dual durometer’ pad with a
harder central tip portion in order
for it to be usable in a restricted
areas such as a mould cavity.
Tampoprint have developed a
centre-less high-speed pad printing
machine for cylindrical objects.
74. Screen printing
Paste ink is pushed through a nylon
or polyester woven mesh
selectively coated with an image-
bearing resist, using a squeegee in
order to decorate a component. The
process is extensively used for
decorating plastic bottles. Most
curing is by UV. Companies such
as Dubuit and OMSO have
developed CNC-controlled
machines in order to print complex
shapes, but the process requires a
more-or-less flat surface for the
length of the squeegee. Tapers up
to about 200 can be tolerated.
Recent developments have
centred around automatic screen
cleaning for printing resists in
electronic applications. Stork have
developed an electroformed rotary
screen able to print finer detail and
thicker deposits onto flat substrates
than conventional screens. DTG
International have developed a
frame that does not require a
separate tensioning device.
75. Sleeving
A pre-printed and heat-retractable
sleeve is placed over the
component. Placement accuracy is
limited, and there is a no-print
margin.
Sacmi have developed an inline
printing and sleeving process for
cylindrical objects. Eos have
developed a TPE impact-resistant
sleeve for bottles. Sleever have
developed a range of tactile
finishes, and Kureha have
developed a heat-shrinkable barrier
film.
76. Sublimation printing
A pre-printed film decorated with
sublimating inks is pressed against
the component under heat.
Sublimation causes the decoration
pass into the vapour phase and be
absorbed by the plastic up to
several tenths of a millimetre.
Recently, Alcan Packaging
Beauty (Albéa) have developed
processes for sublimating a fibre
brush without deforming the fibres.
Flextronic have developed a
process for vacuum forming a pre-
printed sheet over a 3D object in
order to sublimate, and Elbe
Technologies have developed a
fluidized bed process for
sublimating 3D objects.
77. Thermal transfer printing
A coated ribbon is used. A digitally
controlled thermal printhead is
used to melt the coating onto a
substrate in a resolution of up to
300dpi. The process is mostly used
for marking, for example UPC and
EAN codes. Suppliers include
Avery Dennison, Markem, and
Leibinger.
A ribbon providing improved
image uniformity and abrasion
resistance has been recently
proposed in US20110262666A1.
78. Water decal application
Waxed paper sheets are printed
with multi-colour images that
detach when wetted with water.
The detached ink film is usually
manually transferred to an object.
The process is widely used for toys
manufactured in low cost countries.
79. Water transfer printing
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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
Also known as ‘Cubic’ or
‘Hydrographic’ printing. A pre-
printed sheet is placed on water so
that the ink peels off and floats on
the water surface. A component is
then dipped into the water so that
the ink film is transferred to the
component. Positioning accuracy is
limited, so this process is mostly
used for randomly applying
decorative multi-colour patterns or
images to a component.
Taica Corporation have recently
developed a process for integrating
a post-curable UV coating so as to
avoid a post spray operation. DIC
Corporation have developed a 3D
effect by incorporating swelling
inks in the décor.
Inorganic coating
80. Aerosol jet
This process is offered by
companies such as Optomec and
Reinhausen. This process competes
favourably with inkjet printing for
applying very precise amounts and
patterns of, for example,
electrically conductive materials for
electronics applications. Other
materials that can be applied are
polymers and ceramics. See
Fraunhofer (link).
81. Atmospheric plasma deposition
See Atmospheric plasma deposition
in the Organic deposition section.
An atmospheric plasma jet process
projects a plasma towards a
surface. Inorganic precursors such
as HMDSO (to produce a silica
film) are introduced.
82. Atomic layer deposition
ALD is an alternating chemical
vapour deposition process carried
out at low pressure that can be
used to low-temperature metallize
plastics with ceramic-type
materials or produce barrier films
thousands of time better than
traditional solutions. Films are pin-
hole free, and are only nanometres
thick.
The process is used by
companies such as Beneq.
83. Cathodic arc deposition
Metal or ceramic cathodes are
exposed to a moving spark in a
chamber under low pressure, and
the material is vaporised.
Vaporized material is deposited on
components placed inside the
chamber. Usually this process is
carried out in the presence of a gas
such as oxygen or nitrogen in order
to deposit ceramic coatings, as in
reactive sputtering. The process is
used to coat electroplated plastic
components, e.g. with gold-
coloured materials such as TiN or
ZrN. Deposition rate is much lower
than non-reactive deposition, and
substrate heating limits rate and
film thickness. Cathodic arc is
preferred to sputtering for colour
control. As with sputtering, the
equipment is substantially more
expensive than non-reactive DC
sputtering.
84. E-beam evaporation
Thermal evaporation from heated
boats or tungsten filaments can be
replaced by a process that
evaporates the metal using high-
energy electron beam. This is used
for multilayer deposition of metal
oxides onto lenses for AR
properties, where higher melting
temperatures are required. The
beam from an electron gun is
magnetically focussed on the
target. Deposition rate is very high
(10-250 nm/sec), and films tend to
have internal stress.
85. Electroplating
Electroplating is a long-established
method for plating plastics
materials. Parts are racked and
immersed in a series of baths in
order to produce a total inorganic
film thickness of several tens of
microns, with a final layer which
can be real gold or chrome. A
decorative finish may consist of
nickel, copper, chrome and a flash
of gold.
Various alternatives to
sulphochromic chemistry for
treating ABS for adherence have
recently been proposed BASF,
ISPA (Alencon), Incertec,
Stremsdoerfer (Jet Metal), Byd,
Pegastech and Toyota.
86. Flame deposition
This is a process developed, for
example, by nGmat
(www.ngimat.com) in their
NanosprayTM Combustion process
technology.
87. Ion beam deposition
Ion-assisted deposition (IAD) helps
improve e-beam problems of
adhesion and porosity by directing
ionized argon atoms onto the film,
thereby increasing the energy of
the oxide being deposited. IAD
assistance produces more compact
films, which, for example, can
increase refractive index by a value
as much as 0.2.
Several recent applications have
been developed, particularly for
improving AR layer deposition onto
lenses.
88. Laser ablation evaporation
An alternative to e-beam or thermal
evaporation used for temperature-
sensitive substrates.
89. Low pressure plasma enhanced
chemical vapour deposition
(PECVD)
Chemical vapour deposition has
been made possible for heat-
sensitive substrates such as plastics
by the introduction of a plasma.
Although this is usually carried out
under low-pressure, shorter
throwing distances are possible at
atmospheric pressure. A precursor
is introduced into the plasma and is
deposited onto the plastic surface.
The best known application is the
deposition of thin films of silica
(SiO2) from HMDSO precursor.
This process is used to protect
vacuum metallized surfaces in the
manufacturing of automobile
reflectors, and also to apply
scratch-resistant coatings to
plastics such as PC and lens
materials. By manipulating the
amount of oxygen in the chamber,
SiOx can be deposited, and if ‘x’ is
reduced to slightly lower than the
value of 2, oxygen barrier is
obtained.
Kirin Beer has recently
developed an improved process for
depositing DLC on the interior of
PET bottles with less discoloration.
Krone has developed a new
technique for internally coating
PET bottles with SiOx. New
developments have also been
proposed by Cavonic and APPE.
Sidel market their Actis process for
internally depositing amorphous
carbon and KHS their Plasmax
process for SiOx.
90. Silver reduction
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 101 PROCESSES TO DECORATE OR SURFACE TREAT PLASTIC COMPONENTS
Silver reduction is a process
traditionally used for metallizing
mirrors, but has also been used for
3D components in a spray process.
Silver nitrate solution is merged
with reducer in order to deposit a
thin film of silver of the surface,
which then has to be rinsed and
dried. Silver does not quite have
the bright colour of aluminium, and
can also react with moisture to
tarnish, but the process is a lot
simpler to integrate with
basecoating and topcoating, all
operations done on the same
conveyor. In recent years JetMetal
have introduced a more benign
chemistry for this process.
91. Sol-gel coating
Thin hardcoats and barrier
coatings such as silica can be
deposited by dipping or spraying
with colloidal solutions also known
as Ormocers. Heat is required in
order to precipitate the film, and so
this process finds limited use on
temperature-sensitive plastics.
L’Real have recently proposed a
process for coating the inside of
translucent containers in order to
produce a non-migrating colour.
92. Sputtering
Sputtering is an alternative to
thermal evaporation, and is the
second most common physical
process for metallizing. It is carried
out under low pressure. Sputtering
of ‘targets’ is obtained by
bombarding them with ionized
atoms in a magnetically controlled
plasma, usually in the presence of
argon as an inert gas. In non-
reactive sputtering, the target is a
metal, such as aluminium, titanium,
chromium, brass, or an alloy such
as copper/aluminium or stainless
steel. The metal or alloy is
deposited on all surfaces present in
the vacuum chamber.
Reactive sputtering typically
takes place in a low-pressure
atmosphere also containing oxygen
or nitrogen, and acetylene.
Sputtered metals combine with
these to produce ceramics, some of
which have gold or silver colours.
Gold colours, for example, can be
obtained from TiN, TiCN, ZrN, and
ZrCN.
The energy level of projected
atoms being several times higher
than with thermal evaporation,
adhesion is better. Most metals can Two surfaces are spun against each
be sputtered, which is not the case other in order to produce a weld.
with thermal evaporation
processes. The large surface area 100.Ultrasonic welding
possible with targets makes this Ultrasonic energy is used to weld
process ideal for small in-line two components together.
machines equipped with load-locks
where total cycle time can even be 101.Vibration welding
as low as a few seconds (see DVD Similar to spin welding, whereby
production). vibration is used to fuse two
New rapid-cycle sputtering materials together.
equipment has recently been
proposed by Marca, Tapematic,
VTD, and Impact Coatings.
93. Thermal evaporation
Thermal evaporation from heated
boats or tungsten filaments in a
low-pressure atmosphere became
common in industry in the 1950’s,
mainly for decorative processes,
and is still the most common
method of metallizing plastic
components. The metal source is
relatively small, and the process is
usually carried out in large vacuum
chambers, often 1-2 metres in
diameter. Components are loaded
onto satellites in order to carry out
a planetary motion around the
centrally-mounted filaments.
Assembly processes
94. Adhesive gluing
Glue is applied to a component
surface prior to joining. Curing can
be by moisture absorption, heat, or
UV light.
Dymax have recently
introduced UV-cured adhesives
that change colour to become
colourless upon curing.
95. Friction welding
See Spin welding.
96. Heat welding
Plastic surfaces are welded
together using heat.
97. Induction welding
Induction is used to heat a metal
plate in order to fuse two materials
together.
98. Laser welding
A laser is used to weld two
materials together. One material
has to be transparent to laser light.
99. Spin welding