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Static Window Film – a Manufacture Process Walkthrough

Window Film Manufacturing Process

The process by which static window film is made starts with a two layers of simple tinted or un-tinted polyester (plastic) film. These layers form the core of the static cling window film. Other layers are added to create a stable, sturdy window film that utilizes static cling technology to adhere to virtually any surface, with the ability to be removed without leaving any residue.

The polyester film layers undergoes several stages of treatment depending on what the finished product is intended for.
1. PRINT OR COLOR. The polyester film may be printed with a design before starting the process. Printing may be done with a variety of colors and designs, or the plastic may be evenly tinted.
2. COAT. The first layer of polyester film is coated with scratch resistant coating, then with adhesive, using a roller to provide full, even coverage. Additional coatings such as UV inhibitors to protect against sunlight or silicone linings for easy release may also be added.
3. LAMINATE. The untreated layer is laid out, and the treated layer adhered to it by using a rolling mechanism to ensure there are no bubbles and no stretching occurs. This process uses no heat, and is in fact carried out in a cool condition to ensure the plastic maintains its shape and even thickness.
4. METALLIZE OR SPUTTER. In some cases, aluminum may be evaporated onto the surface of the film, using a water cooled roller inside of a vacuum chamber. Alternately, other metals can be applied using a process that knocks atoms of metal onto the surface in a barely visible coating. These steps may be used when a cling film is required to be heat resistant, and are not common in static window films intended for residential use.
5. EMBOSS. Static window film intended for home decoration is often textured with an embossed design. This adds detail and depth to the film on one side, while the other side remains flat for proper adherence to the surface for which it is intended.
6. PACK. The static window film is cut to the desired size and packed. It may be packaged in square sections laid flat, or rolled into tubes and sold in varying lengths.

The static window film manufacturing process uses minimal heat, and pressure is the primary method by which layers are created and solidified. The result is a still-thin, extremely flexible, plain, tinted, printed, or embossed film that will adhere smoothly to the window surface with ease, can be cut to fit any size or shape window, and can even be used on curved glass as is often seen on bay windows, as long as the plane is even (in other words, a cylindrical curve can be accommodated, a spherical curve cannot.)

Static cling technology allows homeowners to renovate or decorate their home without extreme expense, using an environmentally friendly material. Window film can provide protection form harmful UV rays, reduce heat entering the room, provide privacy with tinting or “mirror” effects, prevent glare (invaluable in rooms with a television or computer screen) and enhance the looks and value of your home.

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