Identity Solutions

process
Litho printed aluminum
Crimped aluminum
Aluminm in-mold  

application
Mustang Concept Car 

challenge
•Duplicate look and feel of leather on aluminum

solution
Ford designers carried their custom theme across the aluminum trim in this concept car with a decidedly non-aluminum finish.  The wrapped leather trim is aluminum printed with a custom faux leather finish.  The unique finish is an economical option making use of the production tooling.  Development of the finish began with baby hornback crocodile skin.  Our designers translated the leather finish onto aluminum using a combination of traditional metal decorating processes.  Key to the success of the concept was alignment of the pattern across mating parts in the vehicle.

process
Aluminum in-mold and brushed aluminum
In-mold decorated polycarbonate

application
Whirlpool refrigerator

challenge
•Integrate aluminum and plastic trim into one component
•Expand use of metal trim to include back wall of ice and water dispenser

solution
Previous Whirlpool ice and water dispensers used the aluminum in-mold process to add a stainless steel look to the frame of the dispenser.  This generation pushes the use of metal in the design further incorporating aluminum trim into the back wall of the dispenser, the drip tray and spigot.  The metal surface is desirable not only for its look but for the cool touch it offers.  Consumers see and feel an authentic metal surface.  The designers and engineers at Whirlpool also emphasized the need for a smooth transition from the plastic component to the metal trim in the design.  The plastic overlay uses the in-mold decoration (IMD) process to create a functional overlay with backlit features.

process
Brushed aluminum
Litho printed aluminum
Crimped aluminum
Aluminm in-mold  

application
Cadillac Escalade 

challenge
•Create trim with multiple finishes and illusion of being two trim pieces

solution
This interior is taken to a new level of luxury and sophistication featuring trim combining brushed aluminum with a printed burl woodgrain.  The woodgrain was developed in collaboration with the designers at GM.  A recessed groove between the finishes helps to differentiate the surfaces facilitating the look of separate trim pieces.  This option minimized the number of part numbers and assembly involved in this program.  The finishes are applied in the flat sheet and formed afterward.  A clear topcoat protects the finishes during the forming process.  Key to the success of this program was the development of the finishes to align with the debossed groove. 

process
Screen printed aluminum
Brushed aluminum
Crimped aluminum

application
Volvo C30 Interior Trim

challenge
• Interpret nautical chart theme on aluminum trim

solution
The pattern on the floating center stack was inspired by ancient nautical charts.  Longitude, latitude and dashed directional lines are layered on a brushed background.  Screen printed texture adds dimension.  Our designers worked with Volvo design to develop the custom finish.  The idea began with a design brief followed by a series of sample developments fine tuning the custom aluminum finish.  The center console tooling has been used by Volvo to create multiple trim options for various cars.  The attention to detail in the trim design allows Volvo customers the flexibility to make detailed interior choices choosing from fresh modern style cues.  The high level of craftsmanship and custom finish shown on the console trim are carried across the interior door handles.

process
Screen printed aluminum
Brushed aluminum
Aluminum in-mold
Crimped aluminum

application
Mustang Interior Trim

challenge
• Differentiate interior trim across multiple models.

solution
The four versions of interior trim shown here were manufactured using one set of tooling.  Altering decoration on the metal trim was a cost effective way for Ford designers to create distinctly different looks across the Mustang line.  A classic brushed aluminum finish was one options selected for the Mustang trim.  The carbon fiber finish which was chosen also uses brushing and texture to create movement.  The selected dot patternbuilds on the aluminum finish with a transparent grey tint in the background and a clear texture on the dots.  The woven geometric or technical finish uses the same processes resulting in a completely different look.

process
Engine turned aluminum 
Screen printed polycarbonate

application
International Lonestar, Harley-Davidson Truck

challenge
•Recreate classic Harley styling on premium backlit gauges and dash panel

solution
The engine turned finish is a classic mechanical finish often featured in Harley-Davidson trim.  It was chosen for the premium look it added to the aluminum overlay used on the instrument panel.  This part was designed to conform and attach to existing plastic components, eliminating the need to create new plastic parts.  The decorated metal overlay compliments mixed material gauges made of laminated spun aluminum and backlit polycarbonate.  Early collaboration on the project between Harley-Davdison Styling, Navistar and Northern Engraving Design explored the overall look of the dash panels using concept drawings to illustrate design options including finish, font and color.  The engine turned finish was also chosen to accent the personalized shift knob bezel.  The combination of Lonestar originality and Harley-Davidson authenticity is carried throughout the truck.  Additional metal trim details are on the leather seating which features Harley-Davidson Bar and Shield seat badges. 

process
Diamond cut aluminum

application
International Lonestar, Harley-Davidson Truck

challenge
• Design cost effective premium seat badge option for a low volume special edition truck

solution
The Lonestar Harley-Davidson truck's rich black leather seats feature the same Harley-Davidson Bar and Shields that appear on Harley-Davidson motorcycles.  Using authentic Harley-Davidson fuel tank badges on the seating minimized costs on the program.  Navistar worked with the Northern Engraving team to modify the existing contoured tank badge creating a flat version of the bar and shield badge for the seats.  All the badges include embossed and diamond cut graphics on a matte black background.  Two sizes of seat badges were created for the front seatbacks and rear couch bolster. 

process
Engine turned aluminum 

application
Peavey Wiggy Amp

challenge
•Recreate the style of a retro car dashboard

solution
The engine turned finish is a classic automotive dashboard finish and was chosen for the high impact look it offered.  The metal overlay is manufactured from .060" aluminumwith openings stamped out simulating the gauges on a dash panel.  Embossed borders are used to enhance the unique look with graphics screen printed on the aluminum.  The metal control panel is a creative example of aluminum as a functional and decorative component of a product.

process
Screen printed texture on aluminum

application
Harley-Davidson Fuel Cap Cover

challenge
• Duplicate milled surface created in early prototypes

solution
Early modeling of the fuel cap cover insert was done with a mill.  Harley-Davidson designers wanted to keep the fine milled lines in the prototype logo on the production version of the insert.  Northern Engraving designers developed a subtle line pattern which uses a screen printed texture to duplicate the milled look.  The texture is applied in the silver area of the insert contrasting with the matte black background.  It is interesting to see a second version of the insert printed with a black logo on bright aluminum.