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Common Problems, Causes and Preventative Actions for PSI Brand graphics

INMOULD ORIGINAL

Following application an airpocket is noticeble between graphic and mould.

PSI Brand FAQCause:
Air trapped between graphic and mould surface.

Preventative Action:

1. Take extra care during application. Ensure you apply from the centre outwards or from one side to the other. If air becomes trapped, lance with a pin or knife point and roll again to expel air and flatten. 

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Moulded graphic features moderate sunken areas or dimpling on the surface.
PSI FAQCause:
This is a result of air-pockets trapped between graphic and mould during application.

Preventative Action:

1. Take extra care during application. Ensure you apply from the centre outwards or from one side to the other. If air becomes trapped, lance with a pin or knife point and roll again to expel air and flatten.

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Moulded graphic features small pock marks on the surface.
Cause:
Ensure surface area is clean. Use clean cloth and solvent such as Graphic Adhesive Remover to prepare the mould surface for application.

Preventative Action:

1. Ensure you squeegee the whole graphic prior to burnishing to ensure the heat-activated adhesive has full contact with surface area.

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Moulded graphic features a crack.
PSI Brand FAQCause:
The graphic has been stretched or distorted during application creating a stress-point. The crack will start from this stress point.

Preventative Action:

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Moulded graphic has partially or fully peeled off, e.g. has fallen into the plastic
Cause:
The graphic had poor adhesion to the mould. See answers 1, 2, 3, 4, 5, 6 & 7.

Preventative Action:
1. Ensure mould surface is free from release agents or cleaning residues prior to application.
2. It may be necessary to reduce rotation speed with large mouldings to avoid ‘washing’ the graphic off.
3. With larger mouldings ideally apply graphic to a recessed area to avoid wash off
4. Once graphic is applied, lightly spray reverse side with surface enhancer to protect graphic from material erosion.
5. If the mould features a sand-blasted or shot-peened finish we would recommend this surface is lightly sanded, especially with newer moulds. INMOULD graphics work best on a polished or smooth mould surface.
6. Ensure mould surface is cleaned regularly of adhesive residue build up. We recommend every cycle. Residue build up will gas and cause imperfections in the graphics surface.
7. Avoid preloading mould with graphics for the following day’s cycle as graphics can lose adhesion during this period and result in removal of graphic during the mould cycle

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Air bubble formed behind graphic i.e. incomplete bond to plastic

PSI BrandCause:
The graphic properties have been damaged therefore will not bond sufficiently to plastic

Preventative Action:
1. Ensure even pressure is being applied to graphics during application. If graphic is distorted or stretched this will effect mouldability.
2.Take care not to seal reverse side of graphic with liquid agents

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Parts of graphic not sticking to application tape

Cause:
Insufficient bond between tape and reverse side (white material) of graphic. See following steps.

Preventative Action:

1. Apply pressure over graphic and tape. With paper side facing up, hold tape and peel back paper against itself thus exposing the face of the graphic.

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POSTMOULD GRAPHICS

Area where graphic is to be applied melting or distorting.
PSI BrandCause:
Product is being exposed to too much heat for too longer period.

Preventative Action:
1. Do not use electric heat guns, this will simply melt the surface. Use a torch with wide flame adapter to oxidise surface. Best results are found on parts with wall thickness exceeding 6mm (0.25”)  

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Graphic will not transfer onto plastic surface.
PSI BrandCause:
Plastic is not suitable and/or surface is not adequately prepared

Preventative Action:
1. Ensure graphic is suited for application to the plastic material used.
2. Surface temperature is too cool. Refer to temperature specified in guide and video.
3. Ensure you squeegee the whole graphic prior to burnishing to ensure the heat-activated adhesive has full contact with surface area.
4. Burnish until transfer is noticeable. The transfer sheet will begin to shift about and you will notice air between the transfer sheet and graphic. We recommend our Air-burnishing tool for optimum results.

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Air bubbles appear on the graphic surface following transfer and are easily scratched off.

PSI BrandCause:
Air has become trapped bewteen the graphic and plastic surface.

Preventative Action:

1.Ensure graphic for application to plastic material used, see Technical Data sheet 

2.Surface temperature is too cool and not oxidised. Refer to guide, note also harder plastics require increased temperature to that specified in guide. 

3.Ensure you squeegee the whole graphic prior to burnishing to remove air-bubbles and activate adhesive. 

4.Burnish until transfer evident. Note transfer sheet may change colour, shift about, and start to lift from graphic. For best results use an air-burnishing tool 

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Different coloured bubbles and cracks appear in the graphic during final heat stage.

Cause:
Graphic being exposed to extreme heat for prolonged period.

Preventative Action:
1. Apply less heat and ensure you use even heat source by applying flame in brush-type strokes, rather than intense flame in one area. 

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Graphic is easily removed from plastic surface after application

Cause:
Insufficient bond between graphic and plastic part

Preventative Action:

1.Ensure graphic for application to plastic material used, see Technical Data sheet 

2.Surface temperature is too cool and not oxidised. Refer to guide, note also harder plastics require increased temperature to that specified in guide. 

3.Ensure you squeegee the whole graphic prior to burnishing to remove air-bubbles and activate adhesive. 

4.Burnish until transfer evident. Note transfer sheet may change colour, shift about, and start to lift from graphic. For best results use an air-burnishing tool 

5.Increase flaming in final step, noting graphic change in appearance from smooth to wrinkled, then back to a smooth surface. Test once product is fully cooled and returned to normal state 

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INMOULD XTREME

Following application an airpocket is noticeble between graphic and mould.

PSI Brand FAQCause:
Air trapped between graphic and mould surface.

Preventative Action:
1. Take extra care during application. Ensure you apply from the centre outwards or from one side to the other. If air becomes trapped, lance with a pin or knife point and roll again to expel air and flatten.

Go to Guide

Moulded graphic features moderate sunken areas or dimpling on the surface.

PSI Brand FAQCause:
Adhesive and/or liquid residue likely evident on mould prior to application.

Preventative Action:
1. Ensure surface area is clean. Use clean cloth and solvent IPA or alcohol wipes, to prepare the mould surface for application. 

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Moulded graphic features a crack.
Cause:
The graphic has been stretched or distorted during application creating a stress-point. The crack will start from this stress point.

Preventative Action:
1. Ensure you squeegee the whole graphic without force, gentle pressure is required, especially on warmer moulds.

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Moulded graphic has partially or fully peeled off, e.g. has fallen into the plastic.

PSI BrandCause:
The graphic had poor adhesion to the mould. See answers 1-8

Preventative Action:
1. Ensure mould surface is free from release agents or cleaning residues prior to application. Use tape-test as shown in video to confirm mould surface is ‘graphic ready.’ 
2. It may be necessary to reduce rotation speed with large mouldings to avoid ‘washing’ the graphic off.
3. With larger mouldings ideally apply graphic to a recessed area to avoid wash off
4. Once graphic is applied, lightly spray reverse side with surface enhancer to protect graphic from material erosion.
5. If the mould features a sand-blasted or shot-peened finish we would recommend this surface is lightly sanded, especially with newer moulds. INMOULD graphics work best on a polished or smooth mould surface.

6. Ensure surface area is clean. Use 2-step cleaning if necessary. 1. remove adhesive residue using spray&scrape method 2. dry surface using fast evaporating solvent.
7. Avoid preloading mould with graphics for the following day’s cycle as graphics can lose adhesion during this period and result in removal of graphic during the mould cycle.
8. Type 5B featuring PTAC™. Move graphic into area on mould surface which is cooler, recommended less than 40°C

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ENHANCE WATER BASED SURFACE ENHANCER

Mould surface area of application dulling and/or brown stains evident

Cause:
Excessive application of ENHANCE resulting in residue build-up on mould surface

Preventative Action:
1. Buff the mould surface and apply in lighter coats. Wipe areas where puddling is noticeable

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ENHANCE runs, puddles and results in mottle effect on moulding
Psi brand enhanceCause:
ENHANCE has been applied to liberally and resulting in uneven and extra thick coating

Preventative Action:
1. As above plus note to apply to minimum mould temperature of 40°C (104°F). Application using spray-gun will achieve best results.

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