Surfaces on Aluminum

 

Getting ready to release the latest mood boards and surface collections requires review and tweaking of finish development. Recently a sneak peak was given for some of the dimensional finishes that are coming.  

A couple of these that I found interesting use familiar pattern structures with a twist - halftones contribute an illusion of depth and dimension.  Silvers, blacks and grays are common colors to begin discussion and review.  This does not mean that you are limited - use the rainbow to help define what could be used for your project.  
 

  

 

The process is cost effective and involves one added decorating operation yet provides such interesting perceived dimension. This type of finish is versatile and has application in any market, to name a few:  

●  Appliance Trim 
●  Automotive Trim
●  Boat/Marine Instrumentation Panels
●  Consumer Electronics
●  Packaging

What would you do with this type of finish?

   

 

Just look at the dimension created when a technical pattern is used in the background!  The border of this nameplate appears to be a higher level than the background, resulting in perceived depth without need for a custom emboss tool.

The layering of mechanical finishes coupled with a textured pattern are what makes up the dimensional qualities of this aluminum nameplate.  It isn't over-powering for the brand; rather the robust background provides an elegant backdrop to showcase the name, without incurring additional tooling operations and expense.  Bringing the pattern in from the edges of the part creates a natural border which has the appearance of being raised up.  The difference between the low gloss aluminum and the high gloss texture of the pattern create additional depth, contributing to the perceived value of the product.

 

Can you incorporate a pattern into your next nameplate or trim design?  

 

Creating Four Distinct Looks Using Common Tools

The Dodge Charger takes full advantage of the versatility of aluminum by updating the metal finish to create four distinct looks for unique interiors.  Both the instrument panel and shifter bezel take advantage of the naturally reflective surface of metal.  Brushing and spinning are used to add depth and movement to some of the finishes while others are layered with texture to add dimension.  Each offers a distinguishing look for real metal trim.

The four versions of interior trim shown here were manufactured using one set of common tooling.  Altering decoration on the metal trim was a cost effective way for designers at Dodge to create distinctly different looks across the Charger line.  The shifter bezel further reduces tooling costs by relying on a machining process to create the crisp edge on the openings in the aluminum in-mold trim piece. 

The four finishes featured on the aluminum trim represent the flexibility of aluminum as a substrate.

• Engine Turn 
• Dimensional Mesh
• Technical
• Carbon Weave 

Engine Turned Finish

Engine turn, the finish once popular on vintage automobiles, is back.  Small overlapping spins are precisely aligned creating movement on this unmistakably metal surface.  A transparent gray tint of color aids in creating a coordinated look with with mating chrome and black components. 

Dimensional Mesh Finish 

A dimensional mesh finish took design cues from other materials in the vehicle.  The simple mesh texture is layered on a brushed aluminum background.  The pattern illustrates the ability to truly customize a finish, drawing inspiration from other materials.

Technical Finish

Crisp precision is rendered in this woven structure featuring selective brushing and texture that combine to create the technical finish.  Sharp geometric shapes are intertwined in exact repetition.  Close examination reveals the intricate definition. 

Carbon Weave Finish

This carbon weave finish relies on both brushing and printed texture to simulate the look and movement of an actual woven carbon material.  The pattern is one of numerous carbon fiber and woven structures available on aluminum to create the look you require. 

 

The aluminum finishes shown here illustrate some of the endless opportunities available to you in designing surfaces for metal trim.  Simple or precise, you customize the finish adding mechanical finishes, color and texture to create the look that represents your design intent.

 

 

 

Request a disc collection to begin exploring the variety of finishes available for panels, overlays and decorative trim.

Geometric Finishes

This short video features some of our most popular technical finishes on aluminum.  This series incorporates small scale geometric structures into their design.  Brushing and printed texture add to the depth of the finishes.  The reflective metal surface adds natural highlights and shadows when applied to contours and forms.  The structures are available as an overall surface or to be applied selectively.  Bright or brushed aluminum accents combine with the patterns to further enhance the overall look.  Customization options include color, scale and process.

How would you use these types of finishes in the background of a nameplate or emblem?  What types of product applications come to mind for trim decorated with these finishes?  Tell us your thoughts in the comments below.

Request a disc collection to begin exploring the options available to you in aluminum surface design.

Although the focus of this blog is on options and processes for patterns and textures on aluminum, the same types of structures are available on plastic substrates.  Our library of metal finishes serves as a starting point for projects involving plastic trim or nameplates.  The surfaces on aluminum can be translated onto plastic using traditional printing processes.  Selective gloss adds visual and tactile interest to the finishes.  Metallic inks are used as alternative to the reflective metal.  Options range from tightly spaced geometrics to woodgrains, patinas and marble finishes.  The options are limited only by your imagination.

Our experience in surface design is a resource available to you whether working on metal or plastic.  The structures add perceived value to graphic overlays, plastic trim and gauge faceplates.  How would you incorporate a pattern into a flexible label?  How about a graphic overlay or panel?  Let us know your thoughts in the comments below.

Samples are available on metal or plastic finishes to begin exploring your options in nameplate and trim design.

This is the second article in a series of articles featuring notes from my co-workers on their favorite finish and details behind the finish.  Our guest blogger is Scott VonRuden.  It is interesting that Scott chose a finish that requires precise registration.  Scott works with registration of finishes every day in his role as screening machine operator in the Northern Engraving Design Center.

		Scott VonRuden Press Operator Scott works in the Northern Engraving Design Center.  He is responsible for color matching and screening for new finish development and prototypes.
My favorite Finish is PAT-3860 which has been done in various colors.  It has four screening operations with very tight registration which can be difficult to run.  When all four operations are put together properly (i.e. on register) the end result looks good and is worth the effort put into making it. The first operation is a resist which can be used with a number of mechanical finishes such as brush, engine turn, engine stripe or what ever one would request. The colors that could be used can range from subtle grays and blues to golds and silvers.  The sky is the limit for the colors that could be used on this pattern.  Opaque colors are an option too.  The last two operations are screen printed textures, which can also have color added to them.  Or a soft-touch could be used to get a rubbery feel in the end result.  This finish could be used in numerous nameplate appliqués such as golf clubs, kitchen appliances and maybe even cell phones, with the soft-touch feel added for and extra effect. This finish could also be used on automotive parts such as sill plates, door trim and to knob inserts. Northern Engraving is versatile in all of the above variables mentioned. This is how we are able to meet the unique design requests of our customers.

 

We've had more than one customer apply this pattern to their decorative trim.  What are your thoughts on this precisely registered finish on aluminum?  Thumbs up or thumbs down? 

Technical Finishes on Aluminum

  

  

  

Geometric shapes repeat creating precise detail in metal finishes.  The geometric textures shown here are based on a simple triangular shape.  Options in color and process result an endless array of possibilities.  Authentic metal surfaces are created when textures are applied over a brushed or bright aluminum.  Addition of transparent tints of cool or warm color shift the metal character of the surface.  Texture applied in a contrasting gloss level creates a tone on tone look.  Black texture adds to the contrast.  A slight change in scale emphasizes the structure further.

This technical finish is one of the most popular surfaces in our pattern library.  Both automotive trim and nameplates have been designed with this pattern.  The finish has a precise technical look and works on complex shapes or curved surfaces.  Some geometric finishes such as a dot patterns may be objectionable when applied to a part with an irregular shape.  The rows of dots run off the part creating the appearance of an unfinished or uneven edge.  This illusion of a ragged edge may be unacceptable.  Technical finishes like the ones shown above avoid this issue.

What application do you see for these types of finishes?  Do you prefer the finishes with high or low contrast?

 

 

 

Technical Finishes

Aluminum finishes taking advantage of the reflective metal surface are our most requested category of finishes.  These types of authentic metal surfaces are popular in automotive trim, appliance trim and electronics.  The simple geometric or technical finishes are often integrated into metal trim or nameplates.

  

Authentic Metal Finishes

A single structure or pattern is used here to illustrate some of the options when creating aluminum finishes that feature the look and feel of metal.  The basic process for all three finishes involves screen printing a texture on aluminum.  The first finish uses a soft touch texture printed on low gloss aluminum.  The pattern has a technical look with a slightly softer touch.  The second finish contrasts a low gloss black texture against bright aluminum.  The last finish uses a metallic texture on bright aluminum creating an etched look.  Forming the finishes creates natural highlights and shadows that follow the contours.

  

Pattern Variations

Technical structures shift in appearance when combined with darker or opaque colors as shown here.  The first finish contrasts low gloss black texture against low gloss medium grey.  The combinations in color and process are endless creating a diverse range of possibilities.  High gloss texture screened on high and low gloss black in the next two finishes creates uniquely different looks.  When applied selectively, allowing real metal graphics, boarders or accents to shine through, the finishes compliment and contrast the aluminum.

  

Opaque or transparent color are also options in technical finishes.  Texture can be applied in a contrasting color such as black.  A clear texture in high or low gloss is used for a more subtle effect.

The finishes shown utilize a single pattern or structure.  Choice in process and color creates the various appearances.  This texture has been explored in a wide variety of looks and applications.  It has been integrated into automotive trim and numerous nameplates.  How would you customize this finish for your product?  What other technical finish or pattern would you use to create a real metal surface?

Soft Touch Rubberized Texture

One of the many options available when screen printing a texture on aluminum is soft touch.  The rubberized feel stands in contrast to the metal surface.  Since it is a printed process, soft touch can be applied in any number of patterns from dots and ellipses to pinstripes and grids.  Soft touch is screen printed in clear or with color added to the texture.  The finish can be applied selectively and combined with other finishes.

  

The geometric patterns shown here utilize a black soft touch contrasting with low gloss brushed aluminum.  The mixing of cool metal and soft touch texture result in visually and tactilely appealing surfaces.  The aluminum finishes would be appropriate for a number of applications including automotive, electronics and sporting equipment.  You might consider applying the finish selectively to an area of the trim that is touched frequently.

What patterns or surfaces would you like to see explored with a printed soft touch?  What type of products would you integrate this type of finish into? 

Knurled Patterns

Knurled finishes on aluminum are one of our most popular metal finishes.  Knurling is a visually attractive diamond shaped pattern cut or rolled into metal.  This pattern allows you to get a better grip on the knurled object than would be provided by the original smooth metal surface. 

 

Many designers have looked to knurled surfaces for inspiration when creating patterns for aluminum trim or nameplates.  The pattern is a familiar industrial surface with a look of precision and detail.

  

The crisp diamond effect on actual knurled metal is duplicated in knurled aluminum finishes.  The decorative finishes are achieved through a combination of selective brushing and printing.  A texture is printed on the metal to mimic the texture of knurled metal.  The theme can be varied by changing the contrast or the scale of the pattern.

 

We have integrated the knurled finish into our aluminum match box covers.  The finish is complemented with printed borders and a low gloss brushed aluminum surface.  The logo is embossed and features phalynx diamond cut graphics.  The fine diamond shape in the diamond cut logo repeats the diamond theme in the knurled finish. 

The knurled aluminum surface makes this flat nameplate stand out.  The pattern has a texture which contrasts with the bright aluminum border and the matte aluminum background in the center of the nameplate.

I think knurled finishes on aluminum are most successful when applied selectively and accented with other aluminum finishes.  The knurled effect would also make an attractive trim piece.  How can you see these finishes used?