Systems and methods are described for performing film insert molding (FIM) on a 3D shape, such as a traffic light shell or cover. A film is pre-generated for a surface to be covered by the film, and is inserted into a mold. A viscous material is then injected into the mold and the film bonds to the shell as the viscous material cools and hardens. The film includes a material selected to provide one or more of scratch resistance, improved shell hardness, UV protection, corrosion protection etc., and/or may be selected to alter optical characteristics of the shell.