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Teresa Synakowski, GMN
By Teresa Synakowski | Sep 7, 2017
HTC Star Palette

Metal has a richness and elegance that is hard to match. Real metal has a different feel than plastic and has a high-end look to it. You can capitalize on the elegance of your metal component by adding decorative features as well. Although metal decoration can be a tricky process, GM Nameplate (GMN) has the experience and the skill set for the job.

HCT Europe, a luxury beauty product manufacturer, was working on a project for their client Alcor & Co. They began working with GMN to manufacture the aluminum outer shell of a new beauty color palette named the “Star Palette.” The designer of the palette, John Galliano, wanted it to have the appearance of an antique cigarette case from the 1920’s. On each side of the case, Giliano placed the images of two different “paper dolls” that would be embossed. The background of the palette was to be matte black, while a high-gloss black would be applied to the areas of the embossed artwork. GMN worked with the customers to provide design considerations for manufacturability of the metal shell that aligned with the intended design. In addition, this product was on a tight schedule and needed a quick turnaround for launch, which proved difficult for such an intricate part.

GMN’s Monroe, NC Division was tasked to print, emboss, and form the decorated aluminum shell. To produce this part, first the artwork was printed onto a flat sheet of hi-brite aluminum. The areas that were to be embossed were printed with a transparent high-gloss black ink, which allowed for the brilliance of the aluminum to show through, while the background was printed with a matte black ink for contrast. Using progressive Class A tooling, the aluminum shell was embossed in great detail to bring out the design of the two paper dolls, which can be challenging. GMN was able to achieve the intricate embossing on the part through extremely tight art and print registration. The press closely registered to the lines of the design in order to precisely emboss the desired area, leaving the matte finish flat and the doll designs raised. Finally, the metal sheets were formed to the shape of the palette, creating a clean and rounded edge around the entire shell. The customer wanted the artwork to come all the way down to the edge of the part, which is difficult when stretching the metal during the forming process. But after a few rounds of testing, a process was established that allowed for the part to be consistently formed without distorting the embossing or inks.

After this initial project was completed, GMN provided the customer with several prototypes we created of the same part design but with a variety of color and texture combinations. These samples provided physical representations that exemplified how you can completely transform the look of a current design just by applying different ink processes and decorative finishes.

To learn more about embossing options, check out our blog: Tooling for embossed nameplates.

Prototype samples of the HTC palette's original design using different decorative finishes.

Chris Passanante, GMN
By Chris Passanante | Apr 25, 2017
Plastic insert mold decorated part for the automotive industry.

In the sixth and final part of our blog series covering plastic decoration capabilities, insert mold decorating will be discussed.

Insert mold decorating, known as IMD, is a technology that imbeds a graphic overlay into an injection molded plastic piece. The IMD machine first picks up the graphic overlay with a robotic arm and then loads it into the mold. Molten resin is then injected into the mold which bonds the overlay to the part. From there, the robotic arm picks up the complete part and sets it onto the conveyer belt to be sent to the operator.

IMD is a high volume application using automated processes. In terms of functionality, this technology is utilized frequently for the aerospace and automotive industries because the process ensures strong durability and that the ink won’t wear off of the part. There are material considerations for bonding to ensure that different materials will adhere correctly. For example, if you are bonding two different materials such as nylon and polycarbonate that don’t want to stick together, it can be challenging to figure out how to bond them together. This can be done on first or second surfaces, meaning placing the graphic overlay either on top or below the plastic, and is a design driven decision.

In addition, IMD parts are bulletproof, which is an important feature for many ruggedized industries. Aesthetically, IMD can pull off multiple effects including wood grain, carbon fiber, and high gloss piano black, which are frequently used in the automotive industry. IMD can also incorporate backlighting technologies. Backlighting can be molded in and bonded into the part versus the use of adhesives.

The development phase for IMD can be long, but prototyping can be very helpful for the design as a production tool. IMD is an advanced process through which many GMN customers have found long lasting results. 

To learn more about the plastic decorative options offered at GMN, please visit the rest of our blog series by clicking here

By Sandy Dick | Nov 4, 2016
Adaptive Interfaces overlay produced by GM Nameplate.

Adaptive Interfaces came to GM Nameplate (GMN) to manufacture six different overlays for instruments used in aircraft cockpits. The six overlays had the same shape and colors, but varied in text according to the overlay’s purpose. GMN manufactured overlays for the decoder, encoder, electrical status, oil status, engine temperature, and engine performance monitors.

With GMN’s rapid prototyping capabilities, Adaptive Interfaces was able to receive prototypes quickly to use as a visual for board meetings and discussions. The prototypes were digitally printed using a textured substrate, allowing for fast delivery.

For the production run, the overlay was screen printed. The overlay’s graphics were printed with translucent ink for illumination in dim lighting, and the windows were printed using transparent ink so that the display behind the overlay could readily show through. The adhesive was laser cut and later lined up and adhered to the overlay before fabrication with a steel rule die. The lettering was backprinted and an anti-glare finish was applied the entire overlay.

At GMN, we provide design solutions to help customers navigate through any hurdles to ensure the production of high quality products.