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2017 SPE Decorating & Assembly Division Topical Conference and IMDA Symposium

June 18-20 | Lincolnshire Marriott Resort | Lincolnshire, IL | USA

Sessions

Keynote (Opening Presentation)

Understanding and Using Emerging Aesthetic Design Trends
Bill Dorr, Design Concepts
Why were electronics wrapped in faux woodgrain? What does a stealth fighter have in common with a toaster? How does a nautilus shell become a smoke alarm? Bill Door will discuss this and much more on the subject of aesthetic design trends. The presentation will be visually engaging, educational, and completely original and cover design trends from the past, present, and what he foresees in the future.

Keynote (IMDA Awards Banquet)

The Interface Between Consumers and Package Messaging
John King, APIS Group
The idea of “want” is an abstract idea that many consumers have extreme difficulty articulating. However, “want” can be defined if food and consumer goods manufacturers understand how consumers think. The presentation will introduce a systematic, statistical method of consumer research, Mind Genomics, demonstrating how consumers respond to messaging at both the individual and clustered population levels.

General Session Presentations

In-Mold Structural Electronics (IMSE) for Multifunctional Smart Surfaces
Ron Haag, TactoTec
TactoTek Injection Molded Structural Electronics (IMSE) is a revolutionary technology that changes the way decorated, electronic products such as control panels and HMI surfaces are designed and built. It is a solution that integrates in-mold surface decoration, printed electronics (circuitry, sensors, and antennas) and discrete electronic components (LEDs, ICs, etc.) inside of high visual quality 3D decorated plastic surfaces. Encapsulating lighting, sensors, antennas and controls directly within surface structures significantly reduces the thickness and weight of parts, delivers excellent touch and antenna performance, and simplifies vehicle integration. IMSE brings unique design opportunities for the next generation of products, while simplifying assembly and reducing total cost of ownership.

How Plasma and Flame Surface Treatment Improve Decorating and Assembly Adhesion
Ryan Schuelke, Enercon
In-line atmospheric plasma and flame surface treaters are being used to improve the performance of adhesives on a wide variety of plastics and composites. These systems clean, micro-etch and functionalize surfaces to increase free surface energy and promote adhesion. This presentation will provide insights as to how these technologies improve bonding performance. Industrial decorating and assembly application examples will be shared as well as lab data which will compare the effectiveness of surface treatment technologies on a variety of substrates.

Integrating Digital Inkjet Technology into the Industrial Manufacturing Process
Tim Scully, Engineered Printing Solutions
This presentation will discuss how to identify opportunities for digital inkjet and go through the steps in analyzing the process. It will discuss design considerations when moving into inkjet and how to integrate the digital process into existing work flows (HMI and Communications). It also will include information on selecting the proper components to ensure a successful inkjet print application.

In-Mold Decorating (IMD), In-Mold Labeling (IML), and In-Mold Electronics (IME) Design Considerations for Durable Products
Paul O’Hearn, Profile Plastics
Will explore the similarities and differences between IMD (reel to reel) and IML (FIM) processes for durable products by reviewing production examples. A review of available in-mold hard coats will be conducted, along with the challenges of using IMD/IML to decorate automotive lenses with a hard coat. Lastly will discuss IME function and design as it relates to touch sensors for human machine interfaces.

In-mold Films for Unique Part Decorating
Mike Kerr, Nissha USA, Inc.
 

Utilizing Dynamic Hold Capability of Servo-Driven Ultrasonic Welders in Studying Cooling Phase of the Ultrasonic Welding Process.
Alex Savitski, Dukane
Ultrasonic welding of thermoplastics is widely used by many industries to fuse together two parts in a short time without introducing additional consumables such as fasteners, adhesives, or solvents. The recent development of servo-driven ultrasonic welders, as opposed to pneumatically driven welding machines, introduces unique levels of control throughout the welding cycle. This study focuses on the final phase of the welding process, i.e., the hold cycle, and the benefits that the servo-driven ultrasonic welders can provide to this final phase by controlling both hold distance and the velocity at which this final phase is accomplished.

Plastic Product Decoration – Inks and UV Curing Methods
Jennifer Heathcote, Phoseon Technology
This presentation will cover the nature and benefits of pad, screen, flexo, offset, and digital printing inks for use in product decoration. It will highlight which printing methods are best suited to direct to product printing as well as IML and IMD applications. It will also provide an overview of UV curing technologies including LED and where the respective technologies are effectively being utilized today.

Decorating Breakout Session

UV Paints For Automotive Applications
Phil Kim, Peter Lacke North America
The presentation will discuss the development of UV paints for automotive applications. The reaction mechanisms of traditional thermal cure will be compared with mono and dual UV cure coatings. The impact and application of differing UV sources will be reviewed. Performance differences and limits of the different systems will be compared. Differing scratch resistance requirements of the OEMs will be compared.

SuperChrome™ PVD Coating
Michael Brazil, Vergason Technologies, Inc.
SuperChrome is a thin film stack that replaces electroplating on plastic. With the reflection of plated chrome, it is being accepted by major automotive OEMs after meeting all durability requirements. It uses an environmentally clean PVD process, avoiding all the hazards of chrome plating.

Breakthrough Additives Enhance Plastics “In-Line” Laser Marking: Superior Contrast, Quality and Speed
Scott Sabreen, The Sabreen Group, Inc.
Fast speed, superior contrast and cost-savings are among the significant benefits of incorporating novel FDA-approved additives into polymers for laser marking. Chemical additive breakthroughs produce jet black, light-colored and color contrast for both in-line “on-the-fly” and secondary marking opera¬tions. The advancements in nanosecond Ytterbium Fiber lasers have been instru¬mental to the rapid developments of the newest generation of laser additives.

Assembly Breakout Session

Ultrasonic Welding Technology for Light Weight Structures
Udo Skarke, Herrmann Ultrasonics
Many applications in the machine and automotive manufacturing industry increasingly require the use of fiber re-enforced materials. These types of materials add benefits such as high strength and stiffness to lightweight manufacturing. With increased need and rising production volume, the search for effective and economical processes are playing a central role during the implementation and utilization of endless fiber re-enforced materials with thermoplastic matrixes. This trend triggered the development of a new approach on utilizing ultrasonic technology in modern production lines for discrete but also continued processes. This presentation will outline and cover industrial ultrasonic solutions, developed to meet the need of these challenges.

Instant Bonding of Plastics using Adhesive Technologies
Diva Evans, Henkel Adhesives Technologies
In a market where innovative technology is expanding at an exponential rate and production speeds continue to increase, design engineers must exploit new joining options to maintain a competitive advantage and provide new benefits to their customers. There are a variety of different adhesive options designed to help increase production and reduce work in process. New advances in cyanoacrylates and light cure technologies have made it even easier to achieve these processing benefits in production.

Optimization of Ultrasonic Welding Performance of Eastman Tritan™ Copolyester
Brett Jones, Eastman Chemical Company
Ultrasonic welding is a common method of joining plastic parts without using adhesives, solvents, or mechanical fasteners. Eastman TritanTM copolyester is a relatively new polymer only being commercialized since 2007 and thus may be unfamiliar to the ultrasonic welding industry. Significant traction has been observed in the medical and durable market segments for ultrasonically welding this polymer. TritanTM copolyester offers excellent overall toughness due a lower modulus, however this attribute also contributes to increased weld energy needed during ultrasonic welding. Various weldability factors need to be considered for existing or new TritanTM applications, such as overall design, joint design, optimized processing, welding equipment, and fixturing, to accomplish a robust weld.

In-Mold Labeling (IML) Breakout Sessions

Brand Authentication in 2017 and the Role of In-Mold Decoration
Bob Travis, Ink Works Printing
As global markets tighten with the rise of nationalism, border protection and trade constraints, one can only wonder if the need for brand authentication is as relevant as it was only a few years ago. This paper will explore the current thinking around brand authentication and declining globalization. Bob will share his investigation into understanding the current threat of brand counterfeiting and the technologies that are being employed to authenticate brands. This perspective will include the role of in-mold decoration as a potential counter-measure.

IML-T World Wide Production Systems
Jim Swim, Illig LP
Presentation will show the efficiency, versatility and reliability of In-Mold Labeling-T IMLT. Videos and slides will show examples of products with what has been learned from production lines in the field.

Alternative Label Handling Strategies
Derek Williams, CBW Automation
As In-Mold Labeling increases in popularity, the demand for more cutting-edge technology and lower cost is ever increasing. To meet these demands, CBW Automation is constantly innovating new In-Mold Labeling strategies by applying new perspectives to traditional techniques. One such innovation of particular interest is in label handling. Where most traditional label handling methods involve labels that are pre-cut and stacked, CBW Automation has been researching and developing various roll-fed techniques. In these systems, labels are removed from a roll by the In-Mold-Labeling automation equipment right at the site of the injection molding machine. In many cases, we have found the roll-fed techniques to improve label placement accuracy and reduce costs for molders over the more traditional approaches.

In-Mold Decorating (IMD) Breakout Sessions

Dispatches: Case Studies from the Front
Marshall Paterson, Advanced Decorative Systems
Case studies from the front line. Practical production examples of how a long established supplier of Automotive interior components was able to combine its experience in decorative plastics and printed circuitry to develop first, second & third generation smart surfaces to enhance the driver experience. Based on these examples the presenter will project how he expects smart surfaces to develop in the short and medium term.

Machine and Automation for IML and IMD Applications
Juergen Giesow - Arburg
Consideration criteria for Machine and Automation used for IML and IMD. From simple past through foil to integrated robot system, to high speed dedicated IML cells. Everybody aims for high efficiency and maximum output from an IML/IMD mold cell. Integrating components into the molding cell assure highest possibly efficiency. What can be done with a Molding machine so the entire process is monitored not just regular machine functions.

Design Considerations for IMD Appliance Applications
Dan Haas, Serigraph
Overview of IMD development for appliance applications, including kitchen and laundry products. Will discuss overall product design considerations, including assembly, lighting, capacitive touch, button designs and product performance requirements. An outline of how the IMD process (printing, forming, cutting, molding) should be evaluated during the early product design phase to ensure a robust construction and successful launch.

In-Mold Labeling & Decorating Breakout Sessions

IML Mold Technology for Single Serve Applications
Jordan Robertson, StackTeck
This presentation will cover ultra-lightweight IML cup design, ultrathin trim technology for lightest possible parts, high cavitation IML cup mold technology, and flexible mold technology for thin-wall products.

Digital Printing in the IML World
Jim Murphy, Xeikon
A look at all the benefits digital printing has to offer in the manufacturing of in-mold labels.

The State of the I-IML Packaging Market in North America
Jon Knight, Treofan
Development of the I-IML Market in N America and changes in IML Films, Converting, Supply Chain and Retail trends that have and will continue to facilitate strong growth in I-IML in North America.