A New In-Mould Decoration Process using Real Wood Veneer

Automotive manufacturers use real wood in interiors as a mark of premium car quality. The current manufacture of veneered components is costly, resource demanding and time consuming. An alternative in-mould decoration manufacturing technique is considered here, involving the injection moulding of polymers onto real wood veneer. Experimentation was carried out with two polymers; Polypropylene and Acrylonitrile Butadiene Styrene. These were injected onto three types of wood veneer in a simple geometry mould. All these samples moulded satisfactorily and good contact was achieved between the polymer and veneer. Adhesion integrity was carried out to DIN 53255. The testing resulted in a pass of the PP samples whilst the ABS samples failed. Scanning Electron Microscopy, imagery shows a high level of interaction at the interface with parts made from PP irrespective of veneer types. A high level of polymer penetration is present into the large and small voids of the veneer surface. The high level of penetration has secured a mechanical interlock condition. The samples produced from ABS showed a very poor level of polymer penetration.