Scratches in the clear window of the lens. 20-30% fallout of parts on the customer’s production line.
Separate the lens and the 3M VHB adhesive. Manufacturing overlays with clear window is a difficult task for any printer, even MSI.
The pictured lens is made from a .080 hard coated polycarbonate. The problems happen once the protective masking is removed from the print side. The polycarbonate by nature is soft and easily scratched if not handled perfectly. Once a sheet of lenses is printed they must be handled very carefully in the adhesive and cutting department. Our research has shown that most of the scratches occur after printing in these operations. To reduce the scratches and improve the fall out rate MSI separated the lens and the VHB adhesive, shipping both as separate parts to the customer. By doing this MSI was able to put the protective masking back over the clear window as the parts come off the printing press.
Taking it one step further…. Since our customer had never received the parts this way, MSI engineered the adhesive/lens to be easy to apply and produced a video to teach the customer’s production personnel how to expertly apply the parts.