Proper mold design, label material selection, registration control and process optimization is needed to produce high quality, aesthetically appealing IML/IMD plastic parts.

IMD is a complex and specialized process. There are challenges at every stage of development, from concept to successful production. Here are some key challenges with in-mold decoration (IMD) and in-mold labeling (IML):

• Registration – Precise registration and alignment of the label/decoration with the mold cavity is critical but difficult to achieve consistently.
• Positioning – Keeping the label/decoration accurately positioned during mold closure and injection filling.
• Wrinkling – Labels and decorative films can wrinkle during the process due to high temperature and pressure.
• Entrapment of air – Air trapped between the label/decoration and mold can cause visual defects.
• Excess flash – Flash around the edges of the label is difficult to avoid and trim.
• Label flexibility – The label needs to be flexible enough to conform to the mold contours without tearing or creasing.
• Thermal stability – Labels/decorative films must withstand molten polymer temperatures without deforming or discoloring.
• Bond strength – Sufficient adhesion between the label/decoration and molded resin is required so that they don’t separate.
• Surface finish – Any label/decor imperfection will be visible on the finished molded part surface.
• Resin compatibility – The resin, label material, ink and decoration must be compatible to avoid degredation.
• Cost – IML and IMD molds require higher maintenance and precision, adding cost.
• Secondary operations – Additional trimming, assembly or finishing steps may be needed after demolding.