Secondary decoration operations — painting, printing, or labelling after forming — add time, cost, and potential quality variability to the production of vacuum formed components. In-mould decoration (IMD) techniques incorporate graphics, colour, and surface effects directly into the forming process, producing parts that emerge from the tool already decorated to a high and consistent standard. At Jabro Games, we work with clients to identify where in-mould decoration can simplify their production process and improve the quality of their finished product.
In-Mould Labelling (IML)
In-mould labelling involves placing a pre-printed label or film into the mould before forming. As the heated thermoplastic sheet is drawn over the mould, it bonds to the label, integrating the printed decoration into the surface of the part. The result is a decorated surface that is integral to the part rather than applied to it — resistant to peeling, scratching, and the edge lifting that afflicts adhesive labels in demanding environments.
Colour in the Material
The simplest form of in-mould colour decoration is the use of a pre-pigmented thermoplastic sheet. Rather than forming a natural or black sheet and painting it afterwards, the correct colour is specified in the sheet compound from the outset. The part emerges from the tool already the correct colour, with no additional process steps required. This approach is cost-effective for high volumes but requires a minimum sheet order quantity to justify pigment production.
Textured and Patterned Films
Decorative films — incorporating wood grain, metallic effects, carbon fibre patterns, or other visual textures — can be incorporated into the forming process in the same way as in-mould labels. The film is placed in the mould, the sheet is formed over it, and the pattern becomes integral to the surface of the finished part. This technique is used widely in automotive interior components, consumer electronics housings, and premium retail packaging.
The Benefits
In-mould decoration eliminates secondary painting or printing operations, reducing production cycle time and cost. It produces a more durable decorated surface than most post-forming methods. And it simplifies quality management by reducing the number of separate processes at which defects can occur.
Discuss in-mould decoration options for your project with the Jabro Games team at jabrogames.com.