A recent development in high-pressure forming (HPF) made jointly by Bayer MaterialScience (BMS, Leverkusen / Germany; www.bayerbms.com) and Niebling-Junior (Penzberg / Germany; www.niebling-jun.com) allows polycarbonate film such as BMS’ “Makrofol” HF to be accurately formed at sizes up to 500 mm x 1000 mm. The two companies have developed a prototype, one-part centre console formed using the new process that will be exhibited by BMS at “K 2010” (www.k-online.de) in Düsseldorf / Germany later this month.

Dirk Pophusen, head of business development in the functional films unit at BMS, said the process had been conceived in response to recent increases in demand for larger printed film formats where a high level of accuracy is specified. “Now, it is also possible to manufacture large-area 3D components such as car body parts, centre consoles and decorative trim as one-part components based on HPF-formed polycarbonate films,” he added.

In high-pressure forming, the film is shaped using compressed air at a pressure of 20 to 150 bar. The process is used primarily when PC film needs to be formed gently and in such a way that printed symbols and characters can be positioned accurately. Typical HPF components are display elements such as heating/ventilation facings, 3D speedometers and dials.

The console to be displayed at “K 2010” consists of formable hardcoat film “Makrofol” HF, coated with a “dual-cure” coating and backprinted white. The coating is cured after the forming process using light from conventional UV lamps. BMS said the system produces highly chemical-resistant, scratchproof surfaces with a deep-gloss finish. Backlit symbols can be incorporated through the use of translucent white backlit films and standard LEDs, printed two-dimensional electroluminescent systems or conventional incandescent lamps. It may also be possible to use flexible polymer organic light-emitting diodes that are currently being developed by BMS and its partners – see Plasteurope.com of 25.06.2009. The P-OLEDs could be applied to the back of the film by screen printing and formed with it.

A large LCD, half of which is provided with a conventional film and half with light diffuser film “Makrofol” TP 292, is also incorporated in the console.