Project Overview
An automotive interior supplier required pad printing of multi-color logos on interior trim parts. The project demanded exact color matching to OEM standards, abrasion resistance, and high-volume production capability.
Challenge
The primary challenges included:
- Color Matching: Exact match to OEM color standards
- Multi-Color Printing: Precise registration of multiple colors
- Abrasion Resistance: Must withstand daily contact without wear
- High Volume: 500K+ units annual production requirement
- Automotive Standards: Meet all automotive durability requirements
Solution
Our engineering team developed a comprehensive solution:
Printing Process
- Automated pad printing with precision fixturing
- Custom color formulation to match OEM standards
- Multi-station printing for multi-color registration
- UV-curable inks for durability
Quality Systems
- Spectrophotometer color verification
- 100% visual inspection under controlled lighting
- Abrasion resistance testing per automotive standards
- Adhesion testing for ink bonding
Durability Validation
- Taber abrasion testing (1,000+ cycles)
- Chemical resistance testing (sunscreen, cleaners)
- UV exposure testing for fade resistance
- Temperature cycling for adhesion verification
Results
The project exceeded all targets:
| Metric | Target | Achieved |
|---|---|---|
| Annual Volume | 200K units | 500K+ units |
| Color Match | ΔE < 2.0 | ΔE < 1.0 |
| Quality Escapes | <50 PPM | 0 PPM |
| Abrasion Cycles | 500 | 1,000+ |
| Customer Rating | 95% | 99.8% |
Key Success Factors
- Color Expertise: Precise color matching to OEM standards
- Automation: Consistent printing with minimal variation
- Quality Control: 100% inspection ensuring zero defects
- Durability: Inks and processes meeting automotive requirements
Customer Testimonial
“CoreLMould’s pad printing quality is exceptional. Perfect color match, zero defects in 500K+ parts, and passed all durability tests. Their automotive printing capabilities are best-in-class.”
- Quality Manager, Automotive Interior Supplier