Makrofol® and Makrolon® enable ultra slim and seamless design

Together with Arburg and TactoTek®, we wanted to explore how multi-functional surfaces can be produced using Film Insert Molding. The Night Light incorporates high-quality touch control and lighting functions in an integrated, one-piece part. Arburg and TactoTek® worked with technology partners, including our Covestro team, to create the Night Light demonstrator, which showcases how IMSE™ technology can be incorporated into a functional part that is mass produced using an automated production process.

When integrating traditional electronic functions, designers are often limited by where they can incorporate electronic functionality and the shape the part can take. While IMSE™ technology addresses these challenges, Arburg and TactoTek^® needed materials to manufacture a functional, cost-effective part for the integration of printed and attached electronics in an automated production environment – and all this using only one film. However, the part’s requirements limited the selection of suitable materials.

We provided two IMSE™-qualified materials for the Night Light demonstrator: For the part’s surface, Makrofol^® DE 1-1 polycarbonate film was identified as the right material for film insert molding (FIM) due to its good forming, optical and thermal-mechanical properties. Conductors were printed on the injection molded side of the film. Additionally, the Night Light called for an injection molded resin that is easy to process and has a high light transmission. With low viscosity and excellent optical properties, Makrolon^® LED5102 was an excellent choice to meet these requirements.