By Paul Uglum, president, Uglum Consulting, LLC

Plastic decoration is, by its very nature, a multifaceted and complex set of technologies. Given this, it is important to understand the set of skills and training needed to successfully execute decorated plastic design and manufacture. Unfortunately, there is no one degree or educational path that provides all of the skills and training needed to excel in the profession. That leaves the questions of just how one becomes a skilled plastic decorating engineer and how engineers function in a manufacturing organization.

It is easy to think of a plastic decorating engineer as the manufacturing engineer responsible for the processes used to produce the finished part, but to achieve the best results, engineers knowledgeable in plastic decorating must be involved at all phases, starting with product concept through manufacturing the decorated parts. The obvious reason for this is that, at the concept stage, the decisions made as to which technology to use have a massive impact on both the quality (appropriateness for the application) and manufacturing cost of the finished part.

Due to the complexity, it is rare that a person will have all of the skills and experience needed. In small companies where there may be only one engineer responsible for plastic decorating processes, it is all the more important that the engineer has a network of outside contacts that can provide useful information and insights. In larger companies, the tasks of a plastics decorating engineer may be distributed across an engineering team. In that case, it is important to develop complementary skill sets and to have a process that allows seamless information sharing.

COMPLEXITY OF PLASTIC DECORATING
The primary reason it is difficult to be an expert decorating engineer is the variety and complexity of decorating techniques. Plastic decorating consists of a large number of unrelated secondary technologies. Many processes use coatings and inks, which are applied using different techniques. Metallic decorating choices include thermal transfers; physical vapor deposition (PVD), which uses vacuum technology; and plated plastic (galvanic process), which uses chemical etching and electrochemistry. Many techniques also use lasers for ablation and marking. In addition, a number of complicated processes are used to clean and prepare surfaces for decoration.

Decorating processes themselves tend to be sophisticated and multifaceted. Moreover, each of these decorating processes is surrounded by an entire ecosystem of critical operations and activities. These include raw materials handling and part preparation, both of which feed into the process. They also include the surrounding environment, quality control and assessment (see Figure 1).

In small companies focused on only one type of product, there may be only one or two decorating technologies. In larger companies and companies with a high degree of vertical integration, there may be many technologies separately used or in sequence to produce the decorated parts. When used in combination, not only the processes but also how the technologies interface with each other greatly increase the complexity. Production volume dependency, product mix (some applications are low-volume, high-mix and others are high-volume, low-mix) and the desire for mass customization further add to the complexity in process design and management.

RESPONSIBILITIES OF A PLASTICS DECORATING ENGINEER
The primary functions of a plastic decoration engineer reside in the design phase and in the operation of the process on the manufacturing floor. For a small company with one location, the responsibilities can belong to one person. In large companies, where the responsibilities are in different locations, it is important that there is defined ownership and good communication between the design organization and the manufacturing organization.

In the design phase, the plastic decorating engineer is responsible for understanding the application and choosing the best solution for all stakeholders. It is the engineer’s job to identify the optimum technology and work with the product engineers to ensure that the material choices are appropriate and the limiting design constraints are met. It is important to understand all of the inputs (substrate, materials, process and design) as well as the constraints (both regulatory and economic) (see Figure 2). An awareness should be developed of both future potential industry regulations and societal trends that may impact both customer preferences and behavior. Activities can include developing prototypes for customers and ensuring the choices meet the application requirements, both for appearance and durability. Clear design standards are an important part of this. There always is a risk of copying past successful designs and not realizing that tolerances and shapes are not compatible with differing technologies.

In the operations phase, the plastic decorating engineer is responsible for product launch and actual production. Beyond running the manufacturing process, the in-plant decorating engineer is responsible for creating the manufacturing process routings, quality plans and manufacturing plans, as well as developing the PFMEA and training the production line operators. The engineer also inputs on design for manufacturability and collects and communicates lessons learned. It is important not only to know how to run the operation, but – even more valuable – to understand the “why” behind the process controls. How do changes in the line speed or temperature affect the outcome and why? This knowledge prevents decisions that look good but produce defective parts. The plant decorating engineer often is the first contact in resolving production and field-related issues.

There are several other places where it is desirable to have a good understanding of plastic decorating techniques, as well as each technology’s strengths and weaknesses. One is in the OEM’s (final product manufacturer’s) product design organization and in the group responsible for supplier specifications. This may include those responsible for supplier audit and certifications.

Another important activity is the development and implementation of new technologies. It is critically important to have defined steps that ensure a robust process.

CHARACTERISTICS OF A SUCCESSFUL PLASTIC DECORATING ENGINEER
The attributes that make a good plastic decorating engineer are the same attributes that make an effective design, product or manufacturing engineer. The required characteristics include good attention to detail and a willingness to take the time and effort to develop a deep understanding of the materials, processes, design limits and failure modes. Clear written and oral communication skills, the ability to multitask task and good problem-solving skills also are important. Additionally, it helps to have an openness to new ideas and a commitment to continual learning. This comes from an understanding that no one ever knows everything about a process and that technology is continually evolving.

INITIAL SKILL SET
Engineers find their way into the complex and demanding field of plastic decorating by many paths. Often, they start by working with one process or aspect of the field and develop an interest and the skills needed to excel.

There is not – and probably never will be – a degree specific to plastic decorating, in part due to the variety of manufacturing options and the unique needs of each company. Successful decorating engineers have started with a wide variety of backgrounds, and a range of college degrees make a good foundation for plastic decorating. Degrees in manufacturing engineering, mechanical engineering, plastics engineering, chemistry and color science – are all good starting points.

Learning always is the responsibility of the individual. Companies, however, can do a lot to encourage or, as is too often the case, discourage learning. Companies that seek to be best-in-class and leading-edge create opportunities for their staff to continually learn and update their skills.

FORMAL EDUCATION
By its very nature, plastic decoration requires learning from multiple sources. Not only are there many unrelated technologies, but the knowledge base also is distributed amongst many independent sources. Given this, it is important to seek out multiple sources to develop the necessary knowledge set.

Although there is no secondary education based on plastic decorating alone, there are some bright spots in decorating education. These often are offered in conjunction with plastics engineering programs. Ferris State University in Michigan has a class in Plastics Decorating and Assembly in its Plastics Engineering Technology program. UMass Lowell, Western Washington University and Penn State Erie all offer classes dealing with materials, decorating technologies and associated part design.

SOURCES OF ADDITIONAL LEARNING
Since most of the plastic decoration skillset is developed over time, it is useful to continually pursue training and networking opportunities. Remember that not every source is equally accurate or up-to-date.

Joining a professional society (see Figure 3) like the Society of Plastics Engineers, the Society of Manufacturing Engineers or a similar group provides several advantages, including professional contacts, access to publications and career development opportunities. The downside is that these organizations tend to be limited to specific decorating technologies or specific industries.

Conferences and tradeshows provide both focused training, in the form of presentations, and a window into what is the current state of the art. In addition to attending the presentations and reviewing the exhibits, the most important benefit is the opportunity to develop contacts with those working in the same field. Take the time to meet others and develop relationships that can provide assistance when needed in the future.

When available, plant tours, often arranged through conferences or similar society-related activities, provide a window into what others are doing in similar fields. Even when the technology is different, it is a good opportunity to see useful industry best practices that can be adopted to improve in-house operations.

Podcasts, webinars and virtual conferences also can be useful. Paint and Coatings Academy, offered by Paint and Coatings Industry (PCI), and a Society of Plastics Engineers virtual workshop on plastics decorating and coating are two recent examples.

In-person and hands-on, technology-specific training classes are the most effective way to quickly learn a skill. They are useful even if one has experience in the field. Two examples of face-to-face training are the Inkjet Academy and the Spray Finishing Technology Workshop. Although infrequently offered, they provide not only the basics for beginners but also insights for experienced engineers. They can be a useful model for in-house training. As with conferences, they also provide an opportunity to develop a valuable network of contacts.

Regularly meet with both current suppliers of equipment and materials, as well as suppliers that are not currently being used. If possible, work with their technical reps to understand trends and to have a window into new technologies and materials. Sometimes suppliers also have training and reference materials available for customer use.

The expertise in plastic decoration often is developed, to some extent, in-house, both because of the variety of decorating technologies and the unique nature of each company and its manufacturing capabilities. Given this, internally developed training to ensure capable staff is critical to success. This training should be focused on making sure line operators fully understand the process they control and design engineers understand the critical design features that impact decorating choices. Training should not be static but continually updated as needs and technology change.

REFERENCE MATERIALS
Trade magazines particularly are useful since they tend to provide more current and immediately useful information than technical journals or books (see Figure 4). Like the technical journals, they generally are focused on one or a set of similar technologies. Many have online archives of articles on their websites, allowing research into specific issues or problems.

Industry-specific standards, such as VDA 16, which deals with decorative surfaces and SPI cosmetic specifications, as well as the customers’ standards, can be critical in understanding customer expectations and in communicating across the supply and manufacturing chain.

It is beneficial to put together a library of texts and reference materials on the in-house technologies. These can be advantageous for training new engineers, learning the basics and as a reference for problem solving. The information in books tends to lag current technology by about five years; however, they still are relevant as the fundamentals do not change over time. The publisher Vincentz has an excellent selection of texts on all aspects of coating, such as the “Basics of Coating Technology.” The Society of Manufacturing Engineering has some very good reference books. Even dated references, such as “Standards and Guidelines for Electroplate Plastics” from the American Society of Electroplated Plastics, still contain helpful information. John Kaverman’s book “Pad Printing is a Science (Not an Art)” provides in-depth guidance on pad printing technology. Research what is available and collect the reference works before they are needed.

FINAL COMMENTS
Decorating plastic is a career path that is both challenging and rewarding. Given the dynamic nature of technology and range of customer preferences, plastic decorating always will remain a complex endeavor requiring continuing education and creativity. It is, however, critically important to many industries and can be a very worthwhile career.

Fundamental decorating processes are relevant not only to plastics but also to other substrates – metals, glass and wood. In short, they are a part of almost every object people touch in daily life. Learning about them opens doors to many industries.

Paul Uglum has 43 years of experience in various aspects of plastic materials, plastic decoration, joining and failure analysis. He owns Uglum Consulting, LLC, working in the areas of plastic decoration and optical bonding. For more information, send comments and questions to paul.a.uglum@gmail.com.