Surfaces on Aluminum

Damascus Steel Trim

The distinctive damascus pattern is the focus of this aluminum trim.  The simple, yet elegant, design is our interpretation of the classic damascene steel finish.  Damascene or damascus steel, developed over 1,500 years ago, is recognizable by a charachteristic swirl pattern on the metal surface.  Authentic damascus steel is somewhat rare.  You will find it used on knives.  The finish is created using stratified layers of hard and soft metal. 

Damascene steel is translated on to aluminum trim using a combination of mechanical finishes and transparent inks.  A bright aluminum border accents this trim.  How would you incorporate this finish into trim?  What type of product would you use it on?

Request a sample of this finish to begin exploring the options available to you in creating authentic metal trim for your product.  

The Story Starts with the Finish was the title of our presentation at the IDSA Midwest District Conference this past weekend in Milwaukee, Wisconsin.  The presentation was part of the IDSA Materials and Processes Section's efforts to share information on materials and processes used in product design.  The title was a tie in to the fact that everything Northern Engraving manufactures, from nameplates and badges to appliance and automotive trim, begins with the printing of the finish.  We will feature aspects of the presentation in an upcoming webinar and in articles on the Surfaces on Aluminum Blog.  This short video highlights the finishes featured in the portion of the presentation where we shared the story behind the development of aluminum finishes featured in our trend presentation.

The conference featured a great line up of presenters including:  Ziba Design; HP Design Director, Sam Lucente; Laga Brand Image VP, Mark Dziersk; Fiskars; Radio Flyer; Milwaukee Tool; Harley-Davidson; and Chuck Pelly, founder of Designworks.  Enthusiasm and energy were high as the event took place across multiple locations including: MIAD, the Eisner Museum and the Harley-Davidson Museum.  The Harley-Davidson closing event was fantastic as expected, complete with loud music and motorcycles.

IDSA has two more district conferences in the next two weeks: this Friday-Sunday in Denver, and next Friday-Sunday in Grand Rapids, MI.  Both conferences provide valuable opportunities for dialogue with fellow design colleagues. 

Coined aluminum finishes are popular in automotive trim design.  The authentic metal surfaces can also be integrated into trim for laptops, cell phones and cosmetic compacts. 

Our library of aluminum finishes includes many textured surfaces.  Typically the texture on aluminum finishes is printed on the metal creating visual and tactile relief.  Recently there has been increased interest from designers in creating textures in the surface of the metal using a mechanical process (tooling).  Coining presses texture into the surface of metal.

Nova Trim Finishes

Nova Trim combines standard decorative processes with coining creating interesting surfaces.  Brushed and bright aluminum adds movement while texture creates natural highlights and shadows in the metal.  Stainless steel mesh was the inspiration for both of these aluminum finishes.  Application to a small trim piece adds to the jewel-like quality of the trim.

Textured aluminum trim is a good fit for applications where customers will be interacting with the product through touch.  The steering wheel insert shown above is one example.  Laptop covers, cell phones, cameras and cosmetic compacts are other applications which come to mind.  Textured trim piece can be used to add to the consumer experience of a product.

What applications can you think of very textured aluminum trim?  What type of patterns would you like to see integrated into the texture? 

Request samples of Nova Trim finishes to begin exploring the options available to you in coined aluminum finishes.

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.

Change This... Get That

There are a myriad of options available in creating aluminum finishes.  Consider structure, process and color.  Change one variable and transform the finish.  This article shares a simple exploration in pinstripe finishes on aluminum.  The color, gloss level and process are the same in all four finishes above.  Only the width and spacing of the line is changed.  The results are pinstripe finishes with a different look and feel.  Slight adjustments in the linear structure shift the overall mood of the finish.

Simple adjustments in color and gloss further increase the options available and the resulting effects.  These mood boards are an exploration in the simplicity of a pinstripe finish.  Piano black and brushed aluminum are the base substrates.  The pinstripe finish is printed as a texture adding to the tactile interest of the surface.

Request samples of aluminum finishes to begin exploring the options available to you in creating a custom aluminum finish for your nameplate or aluminum trim.