A truck storage tray, produced from polypropylene (PP) by KraussMaffei using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this case, a textured in-mould label (IML) has been added to the centre (silver), completely concealing the black plastic beneath.

In this ultra-thin product cover demonstrator, a Tepex woven carbon fibre reinforced thermoplastic polyurethane (TPU) sheet is formed and over-moulded with polycarbonate (PC-GF50), and decorated with a Kurz in-mould lamination (IML) film, in a single process on an Engel press.

A demonstrator by Kurz to show off their wood-effect polyester foil hot stamped onto acrylic sheet, which is backlit with integrated tough sensor. A black mask is printed on the reverse side of the semi-transparent foil, which helps control the lighting effect. This kind of technology is used in appliances as well as automotive applications. In car interior applications, where head impact is a risk, polycarbonate (PC) is preferred over acrylic (PMMA).

Cross-section through a reusable foamed cup in polypropylene (PP), manufactured using EcoCore injection moulding technology, that integrates an insulating foam between the two outer skins (MuCell microcellular foam injection). The graphics are applied using a PP in-mould label (IML), which ensures the returnable cup remains recyclable as a monomaterial at the end of its life.

Tivoli clarified polypropylene (PP) reusable cup, injection moulded with PP in-mould label (IML) graphics. Using a single material throughout ensure compatibility of this returnable cup for recycling once it reaches the end of its useful life. However, the ink used for the decoration is trapped between the IML film and moulded cup, and so becomes contamination during recycling and means the cup cannot be recycled back into the same product.

Laptop cover, moulded in PC/ABS, with polyester in-mould label (IML) for decoration and graphics, electroformed bright nickel logo.

Samples of phone back covers using injection moulded PC/ABS with various material integrated by in-mould labelling (IML) and in-mould decoration (IMD). With IML, a film such as PC or PET is printed with colour and graphics, thermoformed and integrated into the injection moulding process by thermoforming and back-injection, locking the print layer between the film and plastic part - the film and moulded plastic form a permanent bond. With IMD, the decorative layer is supplied on a carrier film, which provides support during the moulding process and is removed afterwards, leaving behind the print, hardcoat, or other decoration. With these techniques, fabric, leather, suede, veneer, mirror film, print, haptics and other effects are integrated into the part during moulding, avoiding secondary processes (like printing and painting).

Vacuum metallised polyester in-mould labelling (IML) film, colour coated, formed and combined with polycarbonate (PC) injection moulding

Phillips LivingColors remote, made from injection moulded polycarbonate (PC) with polycarbonate (PC) printed in-mould label (IML)

Games console controller cover, moulded in polycarbonate (PC), with in-mould label (IML) printed and thermoformed PC film for decoration and graphics