possible ways of processing our technical films

Film processing

As a wholesaler for technical films, we supply you with our products in the form of rolls or rectangular sheets in the dimensions you require. We are very flexible when it comes to the dimensions of the sheets and rolls and we are guided by your individual requirements.

Unfortunately, we cannot offer the processing of our technical films. We will be happy to put you in touch with a suitable company that processes films and will be happy to help you. 

At this point we would like to list and describe the most important and most common forms of film processing. Please do not hesitate to contact us if you have any questions or require processed film. Together we will find a customized solution that meets your needs. We look forward to your enquiry!

Materials and their properties

A large number of components or moulded parts are made from technical films. As a specialist in this field, we supply technical film of high quality, which then are further processed in the next steps. 

To do this, the first step is to select the right film solution for the respective application. Depending on the requirements and film processing, we recommend a different material, colour, thickness or surface. We would like to start by listing the most important materials and their properties:

Robust polycarbonate films for high temperatures

High-performance polycarbonate films are particularly impact-resistant and mechanically resilient. In addition, they offer a continuous use temperature of 105 degrees Celsius. In the short term, they can even withstand temperatures of up to 160 degrees Celsius. This makes them an ideal solution for the production of components for temperature-intensive applications.

PMMA film with high UV stability.

Products made of PMMA have the great advantage of enormous UV and weather resistance. This makes these films ideal for long-term outdoor applications where exposure to sunlight becomes a major stress. In addition, PMMA films offer unrivalled light transmission and are therefore ideally suited for applications with high demands on appearance and quality.

Biaxially oriented polyester (PET) films.

PET films are characterised by a high resistance to mechanical effects, temperatures and chemicals. They also have a good tensile strength and tear resistance and are good electrical insulators. They have a low moisture absorption (0.3 %) and a high dielectric strength of up to 180 kV/mm. The very good price-performance ratio makes polyester films a very popular film for various industrial applications. Typical uses of PET are in the production of components for machinery and equipment or in film printing.

PEI films with particularly high temperature resistance.

The PEI film Ultem is a heat-resistant high-performance film made of the plastic polyetherimide (PEI). It has excellent heat resistance up to approx. 200 degrees Celsius. Ultem films are also flame retardant during film manufacture (UL 94 V0 listed) and have low moisture absorption. PEI films are often used for applications in electrical engineering and electronics and the manufacture of electrical insulators.

How can our films be processed?

There are many forms of film processing and film processing options. We would like to list the most important forms of processing from our point of view. In the following we explain how 'films can be processed:

Printing 

Most of our special technical films can be printed. The printability depends on the material of the film as well as the printing process (screen, digital, flexo printing). While films made of polycarbonate and PMMA can usually be printed without any problems, printing on polyester films requires a print pre-treatment of the PET film. This is a print coating that is applied to the material directly by the manufacturer during film production.

The most common printing process is screen printing. Most printing inks adhere directly to our film products. Many inks contain aggressive organic solvents that contribute to adhesion, but can also cause them to fail if not used properly. This is the case, for example, if the solvent has not completely evaporated before further processing of film. All inks should therefore be dried thoroughly after printing and preferably at elevated temperatures. Other option is digital printing, direct printing or the flexographic printing process. If you have any further questions about printing, please do not hesitate to contact us.

Bonding / Self-adhesive solutions

One of the most important way of processing a film is bonding. Films can be processed with numerous adhesive systems, including hot melt adhesives. The choice of the right adhesive depends mainly on the application.

Heat sealing 

Some of our film products are heat sealable. For heat sealing, the impulse, ultrasonic and heat stick (between two jaws) methods gave satisfactory results with most polycarbonate products.

The ultrasonic method is probably the most reliableway and gives peel strengths up to 1.5 N per mm of film width. Impulse and heat bar sealing have achieved peel strengths between 0.5 and 2.5 N/mm. We will be happy to advise you on our heat-sealable products.

Punching 

Die-cutting is one of the most important plastic processing methods. Our technical films can be punched without any problems if suitable machines and tools are used. Steel strip templates, two-part or - albeit only to a limited extent - turning tools are suitable for die-cutting technical films.

Stamping

Films made of polycarbonate with a thickness of up to 250 µm can be embossed without any problems. This makes it possible to create raised membrane switches on film keyboards, tactile labelling or relief-like surfaces. Thicker films up to 0.5 mm can also be embossed under certain circumstances. For 3D effects with films thicker than 0.5 mm, hot forming is recommended.

The service life of raised membrane switches depends decisively on their shape and embossing height, on the film thickness, the switching path and the working environment. The number of switching cycles should therefore be carefully tested in each case.

Thermoforming / Thermoforming / Forming

Many of our special films are ideal for thermoforming because they have a high melt strength. Therefore, they can withstand the temperatures required for thermoforming. 

Typical processes are pressure and vacuum forming, with or without a pre-stretching die over the negative tool, as well as die sinking over positive tools. 

Laser cutting

For smaller runs, cutting films by means of a laser is very popular. This cutting method also allows complex shapes and very precise results. PMMA films and polyester films are ideal for cutting with a laser. Polycarbonate films can also be cut with a laser. However, it is essential that the power of the laser cutter is well adjusted in order to avoid burning the material during the cutting process. 

 

As an experienced specialist and supplier of plastic films of the highest quality, we can offer you to customize sheets and rolls into the required size. We will be happy to assist you if you are looking for companies that process films for you.

Film processing at a glance:

  • Printing - screen printing, digital printing, flexographic printing and more
  • Film cutting - laser cutting and more
  • Forming - hot thermoforming
  • Bonding / welding
  • Punching and embossing
  • Deep drawing
  • Back injection moulding

In addition to the raw material, the right tools and the corresponding know-how play a decisive role in processing plastics. We will be happy to advise you on the processing methods or recommend a suitable company for your individual requirements.

Our service: cutting and delivery time.

Our highest goal is your satisfaction, which is why we rely on the highest quality and established film manufacturers for our products. Our experience as well as the know-how of our manufacturers are an advantage.

As a leading supplier of plastic films, we offer you film solutions in rectangular sheets or as roll or metre goods.

You have the choice of various colours, widths and lengths, which we can deliver directly from our warehouse – starting already at small quantities. Just ask us for the format or size you need and we will make you a suitable offer. We will also be happy to answer any further questions you may have on the subject of ordering, storage, packaging and delivery. If you wish, we can recommend a suitable company for further film processing of our products. Just contact us!

If you have any further questions or requests, please do not hesitate to contact us. We will advise you on the most suitable film material for your application, available colours, film thickness, formats and prices. You can also buy films from us online. Delivery is made directly from our warehouse in Wuppertal, Germany.