Identity Solutions

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
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
Screen printed aluminum
Aluminum in-mold
Crimped aluminum

application
Mustang Shelby Interior Trim

challenge
• Align finish across multiple parts in vehicle

solution
Ford color and trim designers developed the aluminum finish dialing in the size and spacing of the dots.  The interior trim in the vehicle included eight aluminum components, five of which featured this finish and mated up to each other.  The geometric finish meant the success of the program was dependent on the ability to have the finish flow seamlessly from part to part.  Exact placement of the finish was achieved through a print development.  Print development involved screen printing the finish and forming the aluminum in production tools.  Trials were evaluated for placement of dots and artwork was adjusted.  The process was repeated until the exact placement of the finish was achieved.

process
Aluminum in-mold

application
Volvo S60/V70 and S80 Executive

challenge
•Replace plastic roller door with aluminum continuing metal theme throughout vehicle

solution
This project literally started on the back of a napkin.  It began with a wish to integrate aluminum into the roller door for the center console.  Ability to continue the aluminum finish, featured on the doors and dash, across the roller door would upgrade the interior.  Our engineers came up with an aluminum roller door solution fine tuning it through prototypes.  The roller door consists of a series of aluminum strips which are in-molded.  The aluminum in-mold process allows each of the parts to have a sharp edge.  When the strips are placed next to each other they create a continuous smooth surface.  There is no radius between the strips.

process
Aluminum in-mold
Screen printed texture

application
Jaguar XF Hidden Air Vents

challenge
• Design and manufacture concealed air vents
• Accent aluminum trim with chrome beads and graphics

solution view Jaguar slideshow
The almost seamless dash of the Jaguar XF features a band of textured aluminum trim framing the air vents, touchscreen and console controls.  The aluminum air vents disappear when the starter button is pressed and rotate into view when the engine is turned off.  Our engineers worked with Jaguar Design and Engineering to design air vents meeting the aesthetic needs of the project while creating manufacturing feasible decorative trim.  Two challenges in the engineering of the rotary vents were the limited space available and the critical alignment of the components.  The aluminum in-mold process was used to help meet these challenges.

A textured aluminum surface, inspired by a knurled finish, was custom created for Jaguar.  The screen printed pattern is applied selectively allowing the bright aluminum surface to be featured in accent beads and graphics. 

process
Aluminum in-mold

application
Cadillac STS

challenge
• Manufacture durable sill plate with a premium look

solution
Brushed and bright aluminum are combined in the sill plate creating a refined look.  The brushed background contrasts with bright aluminum graphics which are debossed.  Recessing the graphics helps to protect the logo from the normal wear and tear of a sill plate.  To further protect the metal surface, the entire aluminum trim piece is recessed in a molded plastic surround.  The sill plate is manufactured using the aluminum in-mold process which creates one integrated part eliminating steps in assembly.  The aluminum in-mold process also results in a metal trim piece with superior dent resistance.

process
Aluminum over-mold

application
Callaway Golf Club

challenge
• Go beyond previous brand decoration

solution
The popular trend of mixing materials provided the inspiration for our engineers to use plastic as a decorative element for an aluminum nameplate.  The aluminum in-mold process was used to create the dimensional X graphic.  The background aluminum features a spin or radial brush which adds movement.  A precision finish was created through screen printing a detailed texture on black.  The combination of metal, fine detail and plastic comes together in a nameplate with increased perceived value.  The nameplate helps to create  market differentiation for the customer's product and take a premium brand to the next level.

process
Aluminum in-mold and brushed aluminum

application
Whirlpool Refrigerator

challenge
· Upgrade overall look of product by replacing plastic trim with metal
· Match stainless steel finish on aluminum

solution
Aluminum in-mold was required on the trim piece to maintain the sharp edges and lines of the design. The stainless steel look was achieved with a coarse brush and transparent tint of color on aluminum. The aluminum trim continues the contemporary look and feel of stainless steel across the refrigerator. Ability to completely change the look economically by updating the finish allows the same trim piece to be used across different models.

process
Backlit Aluminum In-Mold

application
Microsoft X-Box 360

challenge
-Functional decorative to enhance brand identity
-Meet high order volume requirements

solution
Northern Engraving's Program Management, Engineering and Design teams collaborated with the customer to develop a cost effective backlit button.  The aluminum in-mold manufacturing process incorporates a circular spin on formed aluminum with an in-molded transparent resin.  The aluminum button lights up when the game is live.  Manufacturing and quality teams worked together meeting time and high volume needs.