PROJECTS

Inmoulding of real wood veneer: special synthesis between plastics and natural materials
"Reduce costs, reduce weight and improve logistics." These were, according to the Account Manager at Timmerije, the points of departure for this special product. What does this concern? Here is concerns a bed leg, which comprises an aluminium cast work and a plastic insert that is made of plastics and... real wood veneer. The latter is, of course, "the secret of the smith." When using the technique of inmould decoration (i.e. applying decoration in the mould in one injection-moulding session), how do you ensure that plastics and wood veneer bond well and that - in particular - the latter product withstands the high temperatures of compact injection moulding and does not, for example, crack?

Putting the customer-uncoupling moment later

The bed leg was originally made from solid wood. This was an expensive as well as a heavy solution. Additionally, there was a moment early in the production and assembly process when the bed leg (one of the customer-specific parts of this bed) had to be fitted to the bottom of the bed. Timmerije: "Ensuring that this so-called customer-uncoupling moment occurs as late as possible within the assembly process is the trick. You first fit all the non-customer specific parts and only at the last moment ensure that all the customer-specific parts are fitted to the product according to the customer's desired specifications."

More efficiently, faster, cheaper

With this leg, which Timmerije designed together with one of its customers, the insert panel is thus indeed fitted in the last phase of assembly by clicking it onto the aluminium cast work that has already been fitted to the bed. This may be - according to the customer's wishes - an insert panel with wood veneer but also an insert panel sprayed in a specific colour. The final result is:

• a cheaper solution than before;
• more efficient production and assembly;
• less weight;
• faster logistics owing to a later customer-uncoupling moment;
• limitation of stock raw materials.

And the secret of the smith? "We will not say too much because of competition considerations," said Timmerije. "The science behind the chemical and mechanical bonding between the plastics and natural materials is too important for this." This component emphasizes Timmerije's leading role in terms of process thinking (along) with the customer, mixed component injection moulding and inmould decoration.