What is TOM?

TOM thermoforming

NGF developed into TOM as 3D surface decoration forming.

By TOM, overlaying with skin-material or transfer printing can directly be performed onto a substrate (product) which replaces a mold.

By using film with high functionality, a product can be sealed, waterproofed, or made antifouling.

Video - Introduction to TOM thermoforming machine

NGF rotary machine with two forming stages


NGF shuttle machine with a single forming stage

How it works ?

 Basic Structure
 Preparation
Base product and Film in place

1. Set the base material (product) on the table.

2. Set the skin-material (Decoration Film).

3. Both upper and lower halves of the chamber at
    atmospheric pressure.
 Upper half lowered
1. Upper half lowered, and the entire chamber becomes
    airtight.

2. The inside of the chamber is still at atmospheric
    pressure.

3. Two spaces divided by the decoration film.
 Creating a vacuum & Heating
1. The inside of the chamber (both upper and lower
    halves) made vacuum.

2. Heater turned on to heat the skin material
    (Decoration  Film).

3. The radiant heat softens the film.

4. The heated sheet-material softens and sags;
    however, it is always held horizontally because a
    slight difference in pressure between the upper half
    and the lower counterbalances its gravitational
    weight.
 Base product moved upward
1. The table in the lower half moved upward

2. The inside of the chamber (both upper and lower
    halves) is vacuum.
 Atmospheric pressure exerted
The skin-material is firmly pressed on the substrate
(product) due to the pressure of the atmospheric air
released into the upper half, and the overlay is
completed.
 Compressed air pressure
Compressed air is used if necessary.

The skin-material is more firmly pressed on the
substrate (product) by the compressed air released
into the upper half than atmospheric air.
(Thermal transfer printing)
 Product removed
1. Atmospheric air is released into both the upper and
    lower halves.

2. Upper half is slightly made vacuum for the mold to be
    released easily.

3. Atmospheric air is released into the upper half again,
    and it is moved upward to remove the thermoformed
    product.
 Trimming
Unnecessary skin material parts are hand-cut or trimmed with
a laser trimming machine.

Examples of adopted products

Bathroom vanity door panels (overlaid with wood grain film by TOM thermoforming)
Substrate (product)   after thermoforming by TOM   available on the market
　　

Electronic organ (an injection molded component overlaid with wood grain film by TOM thermoforming)
Substrate (product)   after thermoforming by TOM   available on the market

Nursing care bed (a blow molded component overlaid with wood grain film by TOM thermoforming)
Substrate (product)   after thermoforming by TOM   available on the market

Automobile parts (overlaid with clear/translucent chrome looking film by TOM thermoforming; adopted as lighting parts thanks to the clarity of the film)
Substrate (product)   after thermoforming by TOM   Assy state

   Waterproofing
By using a “transparent film” instead of a patterned film, it is possible to respond [waterproof], [rustproof], [dustproof] such as substrate.

Categorization of 3D thermoplastic film decoration technologies


Overlay and Transfer

 What is overlay...

‘Overlay’ is a decoration method in which film overlaying a substrate (product) remains on it after TOM thermoforming except for the film trimmed around the edges. The film enhances the product appearance with its originality.

 What is Transfer...

‘Transfer’ is a decoration method in which the film is peeled after TOM thermoforming from the substrate (product), and only the decoration layer remains on it; therefore, no trimming is necessary. A protective hard coating layer as well as a decoration layer can be transferred to the product.

This technology has already been adopted to decorate automotive parts such as exterior front grilles.

After TOM thermoforming Assy state

Market vitalized by TOM and its potential

Three dimension Overlay Method, or TOM for short, an innovative 3D surface decoration process, can overlay various products with highly-functional thermoplastic film to decorate them, to enhance their functionality, and to make them appeal to consumers, all of which generate consumer demand, create a new market, and vitalize the industry which supplies materials for the process.
It is a core technology to become an alternative to painting and chrome plating.
Three different technologies are needed to make skin-material, and more than 270 companies in total, each of which specializes one technology or two but not three, now collaborate with each other to supply the TOM market with various skin-materials.
* Trilogy
A trilogy is a series of three movies or novels that have the same subject.
     Request for prototyping parts/component or mass production