Identity Solutions

process
Brushed aluminum
Aluminm in-mold  
Chemical Etch

application
Cadillac Escalade 

challenge
•Upgrade look of existing rubber mat in console armrest by integrating aluminum and plastic trim into one component

solution
The elegant interior of the Cadillac Escalade already integrates aluminum trim into the design.  Adding aluminum to the cell phone pad was a natural progression in upgrading the look.  The metal mat needed to withstand daily wear and tear.  It also needed to protect the phone in the event that it gets dropped.  The solution was to use the through molding process to create rubber ribs.  Inspiration was drawn from the Hummer sillplate.  The finished part combines brushed aluminum molded to soft plastic for a unique mixed material trim piece which is as functional as it is aesthetically pleasing.  The finishing touch in the design was to add the Cadillac logo using a chemical etch process.

process
Omni-Bond Aluminum
Brushed Aluminum
Screen Printed Aluminum

application
Cadillac ATS interior trim

challenge
• utilize a common carrier for three unique substrates

solution
Engineers and designers at GM, Lawrence Automotive and Northern Engraving collaborated on this program to realize the end goal of utilizing a common carrier for real wood, carbon fiber and aluminum trim saving up-front costs on injection mold tooling.  Three unique materials offer three distinct looks for the customization of the Cadillac ATS.  Design criteria for each of the substrates were taken into consideration early on to optimize part designs for the engineering of common carriers.  Standardizing material thicknesses was essential to the success of the program and creating a seamless look within the vehicle. 

Design intent for the decorative aluminum trim plate was to create an intricate layered look conveying precision and sports luxury.  Embossed and debossed details were considered along with diamond cutting.  The final design builds on this intent with an alternative approach which integrates layers of processes combined with mechanical finishes to create the in-laid metal design.  Depth and dimension were achieved without the need to add embossed or diamond cut details.  The aluminum trim showcases decorative aluminum processes creating an eye-catching option for interior trim.

carbon fiber

decorative aluminum

real wood

process
Multi-level Embossed Aluminum
Selective Doming

application
Victory Motorcycle tank

challenge
• develop a new design with the look and feel of a cast metal badge

solution
Collaboration with design engineers at Northern Engraving resulted in an exciting new spin on the typical tank badge. Multi-level embossing enhances the three dimensional shapes creating the look of a cast metal badge. Selective areas of color and text make the brand shine.

In order to maximize the investment, the same badge is formed to fit several different tank contours. This way one process is used in production to keep the brand consistent while only the form varies. A great deal of engineering went into the form of each badge in order to minimize gaps and create the illusion that the badge is part of the tank itself rather than an individual component.

Through teamwork and collaboration Victory Motorcycles and Northern Engraving were able to create an exciting new product that met the needs of the customer in an affordable way while not sacrificing on the quality the brand deserves.

process
Aluminum In-mold
Machined Edge
Engine Turn

application
Dodge Charger shifter bezel

challenge
• develop a cost-effective option for creating a crisp mating edge on aluminum trim

solution
Machined aluminum trim offers several advantages in part design. Key benefits in look and functionality are:

• flexibility in design
• improved aesthetics
• reduced gap between mating parts
• minimized tooling costs

Machining an edge is an efficient option for programs with multiple opening requirements.  Using the CNC to create various apertures for mating component configurations eliminates the need for multiple tools.  This process can be used for interior or exterior edges to create a clean surface free of radii.  The result is a sharp crisp look which minimizes gaps between parts.  It is a cost effective option often minimizing overall tooling costs by reducing the number of dies required. 

The Dodge Charger center console complements the impressive aluminum instrument panel.  Together they create endless opportunities for differentiation with the update of the finish for buzz vehicles.

process
Crimped Aluminum
Aluminum In-Mold
Brushed Aluminum
Screen Printed Aluminum
Bi-directional Brushed Aluminum

application
Range Rover Evoque interior aluminum trim (8 parts per vehicle set)

challenge
• Develop complex aluminum trim giving the appearance of being solid structural elements of the instrument panel

• Design distinctly different finishes allowing the end customer to personalize their interior

solution

Our engineering team pushed the boundaries of the depth of draw as well as the visual appearance on the console trim parts. The base parts, which are fitted to three quarters of Evoque vehicles, carry a tinted linear brush finish. This gives the visual appearance of a brushed alloy structural support for the instrument panel. Customers can then personalize their vehicles with three alternative finishes; a bi-direction brush which creates a floral silhouette, a textured sports finish and a high gloss premium dark finish. Northern Engraving’s designers are currently working on a new finish which was created in conjunction with Victoria Beckham and will be fitted to a Limited Edition variant of the Evoque for launch in 2013.

process
Multi-faceted Formed Aluminum
Screen Printed Aluminum

application
Cobra Radar Detectors

challenge
• Use aluminum trim to differentiate product
• Withstand extreme temperature variations

solution

The multi-faceted geometry of this aluminum trim adds to the eye-catching appeal of both parts.   The designer worked closely with Northern Engraving early in the project visiting our Design Studio and Engineering Group to discuss the project and better understand options in integrating product branding into metal trim.  Trends in finishes were explored with the final design taking advantage of a custom finish.  Careful attention was paid to maximizing impact while minimizing costs.  The trim illustrates effectively how early discussion between supplier and customer results in a design that takes full advantage of options in decorating metal.  The small geometric pattern subtly evolves as it shifts front to back.

A combination of inks and protective topcoats allows the decorative trim to withstand extreme temperatures.

process
Crimped Aluminum
Screen Printed Aluminum

application
Dodge Charger interior aluminum trim

challenge
•Develop complex aluminum trim piece with critical registration 

solution
The Northern Engraving engineering team pushed the boundaries of the depth of draw as well as overall size of the trim piece. The base model features a micro weave pattern that takes advantage of a selective brush as well as texture. Adding to the complexity, tight register was held in order to create a bright aluminum bead outlining the trim piece.

Utilizing the same tooling, additional finishes were chosen to differentiate looks across the Charger line.  The carbon fiber finish combines brushing, printing and texture to create movement. Engine Turn combined with a transparent dark tint was used for an elegant take on a classic finish. Lastly, a technical finish layering a transparent tint and selective texture creates a stunning real metal trim piece for the interior.

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
Aluminum 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.