Appliance makers know—metal and metal
parts often offer the strength, durability, and consistency other plastic
counterparts cannot, in both product design and manufacturing. As design
and aesthetics increasingly become a top priority for consumers, the integration
of metal into products has only increased. And although plastic parts
may offer some versatility, the use of metals and metal parts still prevails
in many appliance applications.
“Plastic is often more versatile; however, there are still many
applications in the appliance industry where metal is the better choice,”
confirms Kevin Casey, process engineer for GM
Nameplate (Seattle, WA,
U.S.). “In regards to stoves and washers and dryers, companies
still use metal the most. Design requirements for these appliances
require corrosion
and heat resistance of up to 400°F,” he explains. “Large
panels still use metal for structural reinforcement, strength, and support.”
Atlas
Steel Products Co. (Twinsburg, OH, U.S.) President Lawrence J. Burr
agrees that although plastic parts do offer certain advantages,
metal
continues to offer the stability manufacturers depend on. “Metal’s
advantages continue to be in areas such as longevity, durability, heat
resistance, and relative low cost,” Mr. Burr tells APPLIANCE.
 Northern
States Metals (West Hartford, CT, U.S.) produces a
range of metal parts that were previously considered
difficult to produce due to costs and technological
limitations. The company says that now, however, metal-part
wall thickness can be reduced by as much as 50 percent.
Extrusion walls as thin as 0.030 in and circle sizes
up to 35 in are available. A variety of finishes, including
conventional anodizing, powder coating, and electrophoresis
methods, can be applied and are available with a machine-applied,
peel-away tape to protect the finish.
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Needs
and Wants
In fact, many appliance suppliers predict that the use of metal and metal
parts will continue to increase as appliance trend patterns follow those
of other industries such as the automotive market. Lima, OH, U.S.-based
metal part supplier American
Trim, L.L.C. says it has found that the use
of metal trim, various finishes, and overall shapes and designs used in
the automotive industry are now being applied to appliance production
processes.
“Design trends usually start in textiles and furniture. You’ll
see a lot of bright materials in furniture along with the grains and colors
of woods, which then migrate into the automotive industry, which migrates
into appliances and other areas of product design in the world,”
explains Bob Byrne, vice president of New Product Development for American
Trim.
As the look of stainless steel and a bright metal bring consumers a feeling
of status, appliance producers are anticipating that the metal “color”
itself will become integrated with the other classic colors typically
found within the appliance industry. “Today in the U.S. there are
four main colors—white, black, bisque, and stainless steel,”
Mr. Byrne tells APPLIANCE. “Stainless steel has itself become a
color category. In Europe, the main colors are white, stainless steel,
and aluminum. We’re beginning to see trends in domestic appliances
in North America where aluminum is becoming the bright metal. We predict
that it will become a color of its own in the U.S. as well.”
Even with the ever-constant issue of cost, appliance makers have increased
the use of stainless steel into designs. Some companies believe the bright
metal not only offers durability that other metals do not, but that it
also brings with it a feeling of status and importance to the consumer.
“There is a perceived quality with metal that makes it more attractive
than plastic to many consumers,” says Bob Lewis, assistant vice
president of Product Development for kitchen appliance maker Dacor (Diamond
Bar, CA, U.S.). “In the case of appliances, the look of a commercial
restaurant is all stainless steel. The consumer assumes that restaurants
have the best equipment, so stainless in their home will bring at least
some of the same qualities that restaurants have.”
Paul Leuthe, corporate marketing manager for Sub-Zero Freezer Company,
Inc. and Wolf Appliance Company, LLC (Madison, WI, U.S.) agrees and says
bright metals and the use of stainless steel in appliances create a feeling
of mystique for consumers. “Everybody likes the classic stainless
steel,” he says. “It brings with it the ‘I’m cooking
and I’ve arrived’ type feeling.”
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An
Atlas
Steel associate operates the Red Bud Industries
precision blanking system. Metal sheets are moved down
through a feeder to a looping pit, where the sheet will
be moved behind the feeder and a metal blank will be
punched for use in a variety of applications. |
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A
Distinguishing Factor
Designing an innovative and truly unique appliance, however, does
not always reside in the initial material selection. Sometimes developing
a differentiating factor is achieved by applying new methods and finishes
to the material.
“When it comes to finishes, there is a wide range of options
for metal,” Mr. Casey of GM Nameplate says. “The metal
finishes we use the most include circular spin, continuous spin, selective
spin, engine-turn, selective brush, and diamond carving on bright surfaces.
Cleanability is a major issue with consumers”
While many companies have increased the use of stainless steel due
to consumer demand, they are finding that preventing or reducing the
appearance of fingerprints on the metal panels is also a priority. “Stainless
steel and bright metals are here to stay,” says Mr. Byrne of
American Trim. “There’s a great deal of focus to provide
a fingerprint resistant finish on bright surfaces. Cleanability is
a major issue with customers.”
Dr. Wolfgang Schlump, materials and applications technology, ThyssenKrupp
Nirosta GmbH (Dusseldorf, Germany) agrees. “Fingerprints can
be seen on all metal surfaces for physical reasons related to the way
metals reflect light,” he explains. “The visibility of
fingerprints can be minimized by microstructuring the surfaces accordingly,
for example, by rolling in depressed and raised areas, while at the
same time slightly matting the surfaces.”
ThyssenKrupp’s NIROSTA® steel is said to help to eliminate
unwanted effects while maintaining the appearance and integrity of
the metal. Using a conventional decorative surface, called standard
designation 2R, a reflective shine is used to create a base for other
finishes. Applied during the cold-rolling process, the 2R surface method
is produced by using polished rolls. A second method, referred to by
the company as a silvery matte appearance or 2B surface, is annealed
and pickled after the cold-rolling process, which roughens the metal.
After the metal’s surface has been treated, a variety of methods
are used to produce a final finish. NIROSTA finishes rely on grinding,
polishing, blasting, and patterning to achieve desired results.
Several metal companies have started to develop and apply different
coatings and finishes to the metal in order to help alleviate the problem
of fingerprints due to consumer demand. The process of blasting the
metal surface is increasing with popularity, as it creates a sleek,
satin finish to stainless steel and aluminum. According to Dr. Schlump,
blasting results in an even, non-directional matte finish. In the process,
sharp or rough materials such as glass beads, sand, or ceramic particles
are used to decrease the brightness of the metal by creating a matte
look or a smooth finish.
Unlike traditional brushed finishes that leave unidirectional patterns,
bead blasting stainless steel leaves a multidirectional finish, which
reportedly allows it to withstand scratches from scrubbing and use.
American Trim is achieving similar results on stainless steel and
aluminum using a different method. Instead of actually blasting the
metal with physical objects, the supplier is applying a screen-printed
coating to achieve the look of bead blasting without going through
the actual process. The unique coating is applied and cured and provides
an artificially frosted finish to the metal.
 Dacor
(Diamond Bar, CA, U.S.) is just one of the many appliance
companies offering products in stainless steel in a variety
of finishes. The company’s Epicure 30-in range and
raised vent features a bead blast finish, helping the metal
to resist scratches while providing an alternative look
to classic stainless steel. The oven features an IR ceramic
heater, and the range features 15,000 BTU and a simmer
plate that allows users to evenly distribute a low, constant
heat without further cooking foods. The Dacor Epicure 30-in
Single Oven, 30-in Warming Oven, and Convection Oven are
also pictured. |
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Forming
Priorities
The influence of design is also affecting appliance production methods,
especially when working with metal. “We’re seeing a lot
more sculpted appearance in brands for differentiation to get away
from the white-box look,” says Mr. Byrne of American Trim.
“There’s an incredible amount of effort to differentiate
particular aspects to draw high-end products,” he continues. “Companies
want brand differentiation. They are asking ‘How do we change
the design so we can manufacture it everyday?’ They want low-cost
and high-quality products.”
Dave Leuck, senior vice president of Northern
Engraving (Sparta,
WI, U.S.), agrees that the design aspect of appliances, specifically
their shape, is becoming a top priority among OEMs and consumers. “The
customers are looking for edgier and straight looks, but at the same
time they are asking for a more organic, or overall rounded appearance
to the appliance,” he says.
To accommodate such desired looks, production methods are being altered.
Contrary to simply welding corners and parts together to form the basic
shape of an appliance, parts are now being formed from single panels.
Suppliers, to meet demands, are developing methods to provide drawn
components without stretching the finish, graining, or coloration of
the metal. “We are currently drawing up to 3-1/2 in to 4 in,
which is a challenge,” says Mr. Leuck.
Mr. Byrne of American Trim says that the use metal and metal parts
provides an advantage when drawing components, as it is easy to weld,
grind, polish, and draw to make the end product appear seamless—an
important aspect to the rounded trend. “One of the biggest trends
we are seeing in the industry is the use of drawn components to eliminate
seamed corners, particularly in stainless steel,” he says.
According to Mr. Byrne, the application of drawn components is typically
found on dishwashers, laundry consoles, and cooking back splashes. “It’s
a cleanability issue, and it’s more cost effective, as you eliminate
a production step forming the product from one single panel,” he
explains.
The use of metal and metal parts can also offer other design advantages,
including the use of brand identification, trim, and parts such as
handles or knobs. “Another benefit of metal is being able to
emboss parts in a more defined way,” Mr. Casey of GM Nameplate
tells APPLIANCE. “Embossed metal parts are crisper, making the
logo or name stand out and create a richer finish.”
In addition to embossed metals, pre-painted metals are also increasing
in popularity and use. Mr. Leuck of Northern Engraving says that 90
percent of his company’s work deals with aluminum that is pre-painted
or tinted to the color of stainless steel. “There are a lot of
appliances out there that have stainless steel panels, and they are
usually fabricated on turret punch presses, where the corners are welded
and the process is entirely different,” he says. “With
our materials, we are able to manufacture that look but with a panel
piece of equipment and the tooling process.”
As appliance OEMs research new metal companies and materials to save
costs, they are often challenged with working with a variety of metal
materials. “The competitive nature of the appliance business
and rising steel prices are driving manufacturers to source steel from
a wider range of suppliers, and that steel often will have differing
properties such as tensile,” notes Brett Butterworth, general
manager of New Zealand appliance maker Fisher & Paykel’s
Production Machinery division.
The appliance company says it has developed equipment to handle the
wide variety of metals with automatic or minimal manual adjustment. “Our ‘true
tangent’ folders will fold doors or cabinets using a wide range
of materials without damage by ensuring that the fold bar never slides
out on the material during the folding process,” Mr. Butterworth
tells APPLIANCE.
“Our ‘feelie’ folder system automatically adjusts
the fold angle for different steel tensile,” he continues. “Due
to an increase in the variety of options required by the market, we
have developed machinery that will automatically change over to new
material or models, allowing smaller batch sizes to be processed.”
Money
Management
Even as the popularity of metal grows in appliance design, metal suppliers
and appliance OEMs continue to struggle with cost and an increasingly
competitive market.
“The cost of stainless steel is going up exponentially it seems
like,” says Mr. Leuthe of Sub-Zero/Wolf. “We’re always
looking for ways to not compromise the product from a functionality
and appearance point of view, but at least try to keep costs down to
minimum.” To accommodate manufacturers that want the low cost
of plastic parts, but need the strength and reliability of metal parts,
some suppliers are integrating the two together.
GM Nameplate has manufactured a hybrid part, made by inserting a
plastic component into a metal back panel. “The customer wanted
a plastic part that looked like metal,” explains Mr. Casey. “It
has a spin finish on the front, was formed, blanked out, and resembled
a metal washer.” By combining the metal with the plastic, the
strength for the part was reinforced, but at a reduced cost compared
to manufacturing an all-metal part.
In addition, in order to continue to produce appliances with metals
and metal parts, appliance makers and suppliers are researching various
metals to produce the look of a more expensive product made out of
stainless steel, for example, from a less expensive metal to reduce
overall costs to the consumer. Northern Engraving has started to do
exactly that. “In order to meet the challenges, we are working
with aluminum to develop a combination to come up with physical developments
of the metal and of the coating process to accommodate the desired
look,” Mr. Leuck says.
The continuous threat of international competition also presents
a challenge to both appliance suppliers and OEMs. “Appliance
producers are dealing with offshore companies, particularly those in
China, as they wrestle with their own costs,” says Mr. Burr of
Atlas Steel Products. “We confront this offshore challenge by
working to help our customers reduce the cost of their products. An
example is helping customers adjust their processes and specifications
so they can use 200 series stainless steel in place of more expensive
300 series,” he continues.
Companies are also starting to use different grades of stainless
steel, depending on the application. “We are seeing more applications
where polished 409 stainless steel is replacing 430 bright annealed,” says
Mr. Burr. “We have also seen substitution of 430 stainless in
place of 304 in applications that do not involve food contact,” he
tells APPLIANCE. “We remain vigilant about lowering our costs
so we can help our customers gain competitive advantages.”
Despite rising costs of materials, increased international competition,
and the popularity of cost-effective plastic parts, the staying power
behind the metallic material remains strong. Design has, and will continue
to play a large role in the future development of appliances, and as
long as it does, it looks like the use of metal materials within those
designs will continue as well. As appliance OEMs focus on meeting the
future needs of consumers, the use of metal and metal parts will continue
to stand strong among its material counterparts.
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