Surfaces on Aluminum

Stainless Steel Alternative

The rich depth of traditional bronze sculptor is explored in this Whirlpool ice and water concept.  This bronze finish is an example of the chameleon-like quality of aluminum to be decorated in a variety of metal finishes.  Patinaed, antiqued and distressed surfaces on copper, bronze, titanium or brass are some of the possibilities.

Metal Clad Appliance Trim

Aluminum is decorated in the flat sheet using a combination of mechanical finishes, lithography, screen printing and roll coating.  The inks and topcoats are formulated to be flexible enough for the complex forms common in appliances, consumer products and automotive trim yet durable enough to meet the requirements of the environment.

This appliance trim concept incorporates two complementary bronze finishes into the design.  The outer frame of the ice and water dispenser incorporates layers of transparent inks on selective brushing to create an interactive surface with depth and movement.  The finish uses the aluminum in-mold process to create a robust trim piece.  The back wall of this design features a brushed aluminum with a transparent bronze tint of color.  The generous radius highlights the reflective quality of the metal.  This portion of the concept is mocked up in our prototype shop illustrating the potential for incorporating metal into the back wall.  This idea can be used to create a uniform aesthetic across the refrigerator or, as in this case, to incorporate complementary finishes for a refined look.

What type of product would you incorporate a bronze finish into?  How would you use the wide variety of finishes available on aluminum to upgrade the look of large appliance trim?  Request a disc collection to begin exploring the variety of finishes available for panels, overlays and decorative trim.

Aluminum In-mold Trim

Aluminum trim integrates authentic brushed metal finishes, geometric structures, patinas, woodgrains and custom finishes into simple or complex shapes.  We are often asked how we do this.  Many assume that color and graphics are added after forming the metal.  This is not the case.  All of our decoration is done in the flat sheet.  This facilitates tight registration of graphics or accent beads to openings in the trim or an edge of the part.  Decorating flat sheets also allows alignment of a finish as it flows across mating parts.  Specific areas of a finish can be chosen, for example a particularly interesting area of a woodgrain, to maximize the impact of the finished part.  Each part will then be printed with the exact same area of woodgrain.

Aluminum Trim Manufacturing

Aluminum is decorated in the flat sheet.  The metal is formed after decorating.  If the trim component includes a plastic carrier it is crimped around the plastic or in-molded.

1) printed texture: (optional) high or low gloss, colored or clear
2) topcoat: protective layer which also determines gloss level of the finish
3) decoration: inks/colors applied via lithography, screen printing and roll coating
4) mechanical finishes: (optional) brush, engine turn, engine stripe, spin
5) aluminum:  mill finish or bright aluminum
6) plastic carrier: (optional) aluminum in-mold or crimped metal

A library of finishes serve as inspiration and a starting point for creating custom finishes on aluminum trim.  The surfaces can be customized in color, scale and process.  Or you might pull one off the shelf to be integrated into your trim.  The finishes can be applied overall or selectively.  Multiple finishes, for example a woodgrain and brushed aluminum, can be combined into a trim piece.  The result is a premium look without the cost of multiple components.  Graphics, functional or representing a brand or model, can be integrated into trim.  Embossing the graphics adds to the premium look and can be used to give the illusion of a separate badge attached to the trim. 

Aluminum Trim with Plastic Carrier

A plastic carrier adds rigidity to decorative trim and often includes attachment features.  Most automotive trim includes decorated aluminum attached to a plastic carrier.  The crimping process is used when an edge of the trim is visible in application (i.e. door rail, instrument panel).  The aluminum in-mold process is a robust process providing superior dent resistance.  Applications include center consoles and sill plates.  There are additional advantages and considerations in deciding which process is appropriate for a specific piece of trim or application.  Our engineering group is available early in programs making recommendations for improving part design and lowering costs.

Aluminum trim isn't limited to the automotive industry.  The appliance industry uses the both the crimped and aluminum in-mold process in ice and water dispensers.  You'll also find aluminum in consumer products and electronics.

What questions do you have about aluminum decoration?  Place them in the comments below and we'll try to answer them.  Request samples of trim components to begin exploring the options available to you.

Mix it Up | Aluminum Trim

Consumers are mixing and matching favorite colors and patterns in kitchen design.  Aluminum trim is a natural match for this trend.  Historically aluminum trim has been decorated in white, black or stainless steel finishes.  The possibilities beyond traditional appliance finishes are limited only by your imagination.

Aluminum In-mold Trim

The Whirlpool ice and water dispenser concept design shown here adds personality to appliance design with a brushed leaf pattern.  The aluminum in-mold trim piece uses two direction brushing to define the finish.  The result is a subtle interactive pattern.

This concept shows only one of the many possibilities available in designing a custom finish for appliance trim.  It also illustrates the versatility of aluminum trim as a cost effective option for product refreshes.  Once an investment is made in tooling, the overall look of metal trim can be updated by simply decorating the aluminum with a new finish for new models. 

How would you use the wide variety of finishes available on aluminum to upgrade the look of large appliance trim?  Request a disc collection to begin exploring the variety of finishes available for panels, overlays and decorative trim.