While consumers are used to their new electronic devices arriving with a film layer over a delicate component for surface protection, many don't realize that surface protection films are also used much earlier and throughout the manufacturing process.
Keep reading to learn more about a manufacturer of automotive instrument cluster and head-up display assemblies that needed a surface protection film tape that was easy to apply and remove.
The Application Challenge: Time Saving Solution Required
A North American head-up display (HUD) assembly manufacturer required a die-cut removable film tape to be placed on to the glass surface of their HUD modules before they shipped to their end-user for installation into the dashboard of the automobile. The purpose of the die-cut film tape was to protect the sensitive glass surface from scratching or marring during transportation and installation.
The end-user (the installer of the HUD modules) requested that the surface protection film tape be provided with a pull-tab for easier removal of the piece after installation. This customer was hand-applying blue splice tape to each part, which was extremely labor intensive and time consuming. They ultimately knew this was not a cost effective or high-quality solution, so they decided to call Marian.
An example of a head-up display (HUD) module. Please note that this image is just a representation and not the actual HUD in this story.
What is Design for Manufacturing?
Part of Marian's processes include design for manufacturing (DFM), a practice that focuses on producing parts that are designed to easily integrate into assembly processes.
This can mean parts are:
- designed with additional assembly aids (pull-tabs, extended liners, split liners, etc.)
- oriented / presented in a specific way for assembly by a person or robot (parts on a roll, packed loose in a box, etc.)
- designed for easy use or removal by the end customer
Due to the installation method of this specific HUD module into the dashboard, a typical extended pull-tab would not work well. It was up to our engineers to design a tailored solution.
The Solution: Marian's Raised Pull-tab
Marian proposed a die-cut surface protection film tape (Nitto R100 E-Mask™) with a raised pull tab.
The individual die-cut parts are provided to the customer wound on a roll for simplified handling. The raised pull-tab stands up at a 90-degree angle to the part instead of the typical extension to the side. When it's time for the end-user to remove the film, they can easily pull the raised pull-tab to remove the part.
The ability to create a raised pull-tab within the high-speed rotary die cutting process instead of adding an additional step is an example of Marian’s innovative and industry leading manufacturing capabilities. Marian's custom-built machines allow for assembly aids like this and more to be added in-line.
The die-cut surface protection film tape with a raised pull tab.
Key Takeaways: Benefits of Working with Marian for Custom Pull-tab Applications
- Marian made it easy for the end customer by providing the parts kiss-cut on rolls.
- Our raised pull-tab solution allowed for easy liner removal, saving the end-user time and headaches. Marian excels at these technically difficult processes! These manufacturing considerations are part of our focus on "design for manufacturing".
- Marian's strong partnerships with material suppliers allows immediate access to the industry's best materials for converting.
If you're working on an application that you think would be simplified by the addition of a pull-tab or any other assembly aid, contact us and we'll connect you with a Sales Engineer in your area.
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Marian, Inc. is an ISO 9001 certified converter of custom die-cut components made from flexible materials. We partner with leading material suppliers, and our global capacity is unmatched. This Marian application story, along with many others, uniquely demonstrates our state-of-the-art custom converting capabilities including die cutting, lamination, design for manufacturing, and more. Please contact us today to learn more or to request a quote, prototype, or material sample.
