World Leaders in Polycarbonate Film Technology, Performance, and Optics

Curbell Plastics is a proud supplier of Bayer materials

1.888.00RBELL www.curbellplastlcs.com
Makrofol

and Bayfol

polycarbonate films are clearly

the right choice when product excellence is your goal.
Produced from Bayers MAKROLON

polycarbonate
resins, Makrofol and Bayfol are backed by the
worldwide technological leadership of Bayer. Bayer
films are manufactured to stringent quality standards
in ISO-9001:2000 certified facilities. State-of-the-art
extrusion lines provide the flexibility to provide custom
colors, widths, lengths, and sheets. These high quality
films have the required UL ratings, meet FDA approval,
and are available in an assortment of surface textures.
Bayer films offer the stability, consistency, and strength
to ensure excellent quality in a wide range of applica-
tions. Many times stronger than acrylic, Makrofol and
Bayfol can be easily formed and much more dimen-
sionally stable than polyester. These films form easier,
deeper, and more consistently than other materials,
making the graphics crisper and gloss more consistent
from part to part. Lower stress levels allow for tighter
registration of printed graphics. The superior strength
of polycarbonate allows you to use thinner films and
still achieve the results you desire.
Clearly the Right Choice
Makrofol and Bayfol polycarbonate films feature
outstanding clarity and transparency. They are
produced in a variety of thicknesses, surface textures,
grades, and glosses. You can choose from a wide
range of options, including transparent, translucent,
opaque, and metallic. Custom colors and grades for
laser engraving are also available.
2
Achieving Higher Levels of Innovation and
Excellence in Film Applications with Makrofol

and Bayfol

Polycarbonate Films
Instrument Panel Overlays
Thermoformed Medical Packaging
Indoor/Outdoor Labels and Decals
Mousepads
Automotive Dials
Nameplates
Exhibit and Display Components
Floor Graphics
Automotive Control Panels
Keypads
Chip Packaging
Membrane Switch Overlays
Menu Boards
Film Insert Molding
Electrical Insulation
Typical
applications
include:
3
Outstanding Product Line Provides Creative
Design Options for New Applications
Bayer polycarbonate films offer the clarity, variety of
surface textures, and specific properties you need to
meet the most demanding application requirements.
Graphic Arts Quality
Makrofol

DE and PC polycarbonate films are available

in a wide variety of surface textures, including glass
clear with both sides gloss. These films offer high light
transmittance, excellent surface uniformity, and ease
of processing. All films use pure Bayer MAKROLON

polycarbonate resin. Most meet FDA approval and have

the necessary UL ratings.
Chemical Resistant Blends
Bayfol

CR film is a polycarbonate/polyester blend that

provides improved mechanical and chemical resistant
properties.
Flame Retardant
Makrofol

FR films have flame retardant properties and

can be easily fabricated or printed. They are ideal for
electrical insulation and are available in white and clear.
Light Diffusing
Makrofol

LT and BL films have been specially

developed to provide light diffusion capability which
surpasses the capability of films that rely on surface
texturing for light scattering. Makrofol

LT and BL are
available in natural color and smoke tint. Smoke tint is
suitable for dead front panels.
Specialty Films and Composites
Specialty films have been developed to provide
increased weatherability and durability under harsh
conditions. Makrofol

EPC film is a special composite

film that provides excellent first surface chemical and
UV resistance. Bayfol

AS-A (black) film is suitable for

antistatic packaging of sensitive electronic components.
New Products
A variety of new products have been developed to meet
customer special needs. Those products, designated by
Makrofol/Bayfol DPF or TP names, offer special features
such as unique textures and colors, UV and flame
resistance, high Vicat softening temperature, soft feel,
metallic look, adhesive coating, low stress, etc.
...Clearly the Right Choice
4
Thermoforming
The primary advantage offered by thermoforming is the
ability to achieve deep draws on the formed appliqu.
The process does suffer from registration problems on
the graphic appliqu. This can cause problems where
critical graphic registration is required.
High Pressure Forming (HPF)
Developed by Bayer AG, high pressure forming offers
several advantages. Due to the uniform force applied to
the film, very little residual stress remains in the part.
The inks used to print the film may be heated prior to
forming, allowing the graphic to be formed without
cracking the ink. Since the front surface of the film is
only contacted by the air injected into the tool, rejects
from contaminants are reduced. Automatic presses
built for this process can be considerably faster than
other processes. They have cycle times of seven to ten
seconds, depending on gauge.
Hydroforming
The hydroforming process provides excellent regis-
tration of the graphics to the molded part. However, it
does not allow the films to be heated to increase the
elongation of the graphic inks. It allows for fast tool
setup and changeover. Formed parts exhibit relatively
low stress. The main drawback is long cycle times.
Match Metal Dies
This process has been used for prototypes and low
volume applications. One advantage is that tool halves
can be heated to improve ink elongation during the
forming process. The primary limitation of the process
is that metal tooling contacts the front surface of the
formed appliqu. This can result in gloss variations
and contaminants being forced into the films surface.
Trimming
There are presently three methods being used to
pretrim inserts prior to molding. Die-cutting offers high
quality, low cost trimming and is primarily used for
medium to long production runs. Laser cutting is a
low volume prototype method of trimming parts. Hard
tooling is the choice for high quality, long run parts.
Other Key Parameters
Other key parameters which affect the insert molding
process have to do with design of the injection molding
tool, the location of the film appliqu in the mold,
and the process conditions related to molding the
final assembly.
Bayer Polycarbonate Films and Advanced Molding Technology
Bayer has developed Film Insert Molding (FIM)
technology that can satisfy a designers wish list for
3-dimensional parts. Bayers materials and processes
for insert molding polycarbonate-based films provide
the features you need for quality parts...at reduced costs.
Compound curves
Complex geometrics
Registered graphics
Multiple colors
Opaque or transparent
Selectively textural
Scratch resistant
Long lasting finishes
Film insert molding consists of placing a decorated film,
either flat or formed into the mold of an injection
molding machine. Resin is shot behind the film, bonding
the film surface to the molding resin to form a finished
integral part. The development of water-based and high
heat polycarbonate inks, innovative forming methods,
and precision registering equipment provide major
advantages in part decoration by FIM.
Unlimited decoration possibilities with precisely
registered graphics
Design flexibility including complex designs and
simplified backlighting
Cost savings via productivity improvements such as
reduction in post-molding operations
Many different film and resin combinations are possible
using FIM. Typically, the insert molding process incorpo-
rates the use of polycarbonate or polycarbonate blend
film substrates, allowing a wide variety of injection
molded resins to be used. Key factors to consider in
choosing materials are: the need for heat and/or
chemical resistance; impact resistance requirements;
and aesthetic appearance. Designers must also
consider the compatibility of materials with the
decoration process and graphic construction with the
injection molding resin.
Several different forming methods are being used for
insert molding. Each forming process has its own
benefits and limitations which must be considered in
the design phase.
5
Makrofol and Bayfol can be screen printed using acrylic
and PVC-based inks. Ink adhesion is excellent and no
pretreatment of the film is required. Because of the
films high heat resistance, printing inks can be quickly
dried at high temperatures.
Makrofol can be easily die-cut with a variety of steel
rule dies. For the best overall results in terms of clean
cuts, precision and die longevity, side-bevel rule is
recommended. With this configuration, the long-bevel
side should face the scrap material displacement rather
than the short side bevel.
Makrofol can be thermoformed at a temperature of
190C (374F), with the mold temperature at 110C
(230F). If the film is to be heated very rapidly, it
should first be dried for 3 to 4 hours at 100C (212F).
Except for Makrofol LT and BL films, all Makrofol and
Bayfol films are suitable for cold forming and offer
dimensional stability at high service temperatures up
to 130C (266F) for Makrofol and 100C (212F) for
Bayfol films.
Substrates carrying printed information can be bonded
using transfer adhesives, double-sided adhesive tapes,
screen printed adhesives or two-component adhesives.
For film-to-film bonding, solvents such as methylene
chloride are normally used.
Makrofol and Bayfol can be welded to certain other
thermoplastics such as PC and ABS using ultrasonic
methods.
Gauge: .005 to .030
Width: up to 53
Surface Finishes: Gloss, velvet, suede, matte,
micro-matte, and combinations
In-line sheeting is done at the extruder; sheets are
stacked flat and delivered flat eliminating roll set.
Standard trimmed and squared sheeting is available
for tighter dimensional tolerances.
Masking of gloss surfaces is available for films 7 mil
and thicker. Choices of masking are cling or stick.
Fabrication
Printing
Die-Cutting
Thermoforming
Embossing
Bonding
Welding
Custom Extrusion
Capabilities
Converting Services
...Clearly the Right Choice for Molded Part Decoration
6
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1
1
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Copyright, Bayer Films Americas, 2004 Rev 9/05 Printed in USA
BFCAPBRO9/05
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