In-Mold Electronics (IME) is the extension of In-Mold Decoration (IMD). Thermoformed plastics with decorative coatings are transformed into 3D components by injection molding. IME is the development of existing technology, so much of existing processes and equipment can be reused.

Compared to technology on traditional mechanical switches, IME is able to reduce weight and material consumption by 70%, while requiring fewer parts to achieve the same functionality. Things like functional film bonding and integrating components such as LEDs within IME parts offer clear advantages.

Despite the similarities between IME and IMD, there are still many technical challenges associated with the integration of electronic functions. It must be able to withstand thermoforming and injection molding. Circuits are embedded, so there must be very high manufacturing yields. A single fault can cause the entire part to fail.

Application of IME

Automotive interiors

Smart surfaces are becoming a trend in car interiors. For example, smart surfaces that integrate touch sensors and lighting inside the panels using IME are replacing mechanical switches. IME combines electronic, decorative and mechanical functions in one component.

In cars, smart surfaces can replace mechanical buttons to make minimalist interior. Intuitive and easy-to-use touch areas keep the driver's eyes on the road instead of the display. IME replaces capacitive touch lock sensors. It enables detection under metal, replaces static display buttons, reduces display size and cost, and makes new touch-sensitive display shapes. IME also removes bulky knobs and controls by sensing under solid surfaces.

Smart surfaces can evolve to offer more complex interactions than simple capacitive sensors or on/off buttons. For example, printed pressure sensors may find their way into control panels, allowing for a wider range of inputs. Haptic feedback is likely to be widely integrated, as driving behavior is both more satisfying and safer if the need for drivers to take their eyes off the road is minimized.

The curved glass used in smartphones has also been applied to car interiors. It has the functions of being able to be coated, printed, and bent into a curved surface. It is scratch-resistant and impact-resistant.

IME can make plastic surfaces look like wood, metal or leather. It can be used with backlit information displays, ambient lighting and touch-sensitive control surfaces. The controller interacts with the touch display to control things like cabin temperature and lighting.

Consumer electronics

Currently, there are not many manufacturers focusing on automotive IME. Most of them work hard on consumer electronics or industrial applications. IME can simplify existing HMI surfaces, and even introduce HMI functions to new locations. You can see IME on medical equipment, countertop equipment, and even smart furnitures.

In smartphones, smart surfaces on sides or back of the phone enable natural one-handed control, providing a new user interface for selfies. Ultra-sensitive air triggers and game controls on sides or back of the phone can take gaming to the next level. Replacing the volume, power and mute mechanical buttons can shrink the phone form factor and enable new cutting-edge industrial designs.

In mobile devices, the smallest, lowest power touch interface is ideal for the next generation of augmented reality glasses. IME integrates command and control of smart watches into the bezel. It enables new touch and gesture controls in headphones. It also eliminates false triggers caused by using accelerometer sensors for touch sensing.