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Bond-Laminates will be making hybrid moulding plus IMD (In-Mould Decoration) technology at JEC World 2017.
According to Bond-Laminates, the new process enables fully automatic mass production, without any reworking, of extremely thin-walled yet exceptionally stiff lightweight components with high-quality surface decoration. It all starts with Tepex continuous fibre reinforced thermoplastic composites developed and produced by Bond-Laminates.
“The technology has a wide range of applications, including housing parts for IT equipment such as smartphones, notebooks and tablets, components for consumer goods such as TVs, coffee machines, vacuum cleaners and electric shavers, and even sports equipment,” explains Jochen Bauder, Managing Director of Bond-Laminates. “We will be producing a decorated housing component with walls just 0.6 millimeters thick on a highly automated manufacturing cell that is suited to large-scale series production,” reveals Bauder.
Hybrid moulding plus IMD technology is a one-shot process combining three steps in a single mould – forming the semi-finished composite, overmoulding the formed semi-finished product and painting or decorating it using in-mould decoration with the help of a dry-paint transferred from a foil carrier. Depending on the component, the part’s geometry and the paint system, cycle times can be as short as just 60 to 90 seconds.
The new technology is the result of close collaboration between several partners. Leonhard Kurz Stiftung and Bond-Laminates developed an IMD system coordinated with the process with a special formulation and the necessary mould technology. Based on this, Engel Austria then devised a highly automated manufacturing cell that is suited to large-scale series production.
Bond-Laminates says it will also be using JEC to showcase a number of series automotive applications for Tepex – including an all-plastic brake pedal that is used in cars such as the Porsche Panamera and the Bentley Continental GT. This brake pedal was recently awarded first place in the “Body Interior” category of the Society of Plastics Engineers (SPE) Automotive Awards. Other applications on show will be the rear bumper beam of the Honda Clarity Fuel Cell and a car underfloor protection paneling.
Visit Bond-Laminates in Hall 5A, Stand J11 at JEC World 2017.
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