Metal forming specialist Vestatec has a long history of working with leading automotive OEMs such as Bentley, Lamborghini, Volvo, General Motors, and others. The company manufactures premium speaker grilles and metal interior trim using metal forming, photo etching, and physical vapor deposition coating, and offers a range of assembly and customization services.

Design News asked Mike Bylina, managing director at Vestatec, a few questions about the latest trends, challenges, and technological advancements in metalworking for premium interior trim.

What are the top trends for using metal in interior auto design?

Bylina: There are a number of trends we’re seeing through our work with some of the industry’s most prestigious vehicle manufacturers. Most recently, we’ve seen more OEMs incorporating much larger and more complex metal designs throughout the vehicle interior. For example, manufacturers such as Cadillac are designing metal components far bigger than what the industry has become accustomed to, showing a real glimpse of not only what is possible, but also what might be to come for more automotive brands. 

Customization has also emerged as a major trend, with OEMs looking to meet consumer demand for premium interiors tailored to the individual. Techniques such as photo etching and physical vapor deposition (PVD) coatings have gained popularity with OEMs as the combination of these techniques offers a wide variety of patterns, colors, and finishes throughout the vehicle interior—choices that can ultimately be passed on to the customer. 

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In recent years, the way technology and other functional components have been integrated into the vehicle’s cabin has enhanced significantly. The likes of Tesla have been leading the way with its single-console model, and many other manufacturers, regardless of vehicle price point, are beginning to shift from traditional buttons and switches to much sleeker, minimalist cockpit designs.

This part would have been through multiple stages of press forming at this point. VESTATEC

What challenges do automotive engineers face in keeping up with these trends?

Bylina: For design engineers, achieving perfect A-surface conditions on vehicle interior components is crucial, especially for more premium and luxury outfits, such as Rolls-Royce and Bentley, where imperfections are strictly non-negotiable. This can be tricky depending on the design complexities and the size of the component, but with the right manufacturing processes and technology, a high-quality product can be achieved. 

Yet, for some design engineers, discussing alternative techniques not commonly used in the industry can be a challenge, as there is a lack of awareness about the real benefits these can bring to the vehicle.

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Alternative manufacturing processes can help vehicle designers achieve A-surface conditions without hindering design capabilities. For example, the photo-etching process works within tight tolerances and can achieve accuracies of up to +0.025 mm, making it a superior alternative to more established methods, such as stamping and laser cutting, when creating complex patterns or hole geometries in parts such as speaker grilles. 

However, combining photo-etched parts with traditional coatings like paint or chrome plating can compromise the small holes or patterns within the component. An alternative coating solution, which is growing in demand, is PVD, which is less than a micron thick. Due to its thin application, it is the perfect coating solution for complex patterns, giving parts a decorative metallic finish. Additionally, it is an environmentally clean process, which creates no hazardous waste and components are 100% recyclable at the end of their life span.

Moreover, as it is available in a wide range of metallic color options, PVD is also proving to be a popular choice with styling teams, who are tasked with finding solutions to facilitate the growing demand for customization.

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Are there any new automotive technologies or market needs that present new challenges or opportunities for metalwork (audio, visual, connectivity, sensors, sustainability, lightweighting, or more?)

Bylina: Less is more with the future of automotive, and as we shift more towards electrification, OEMs are designing vehicles with sleeker interiors and consolidated, on-screen control consoles. 

A great example of this shift is the disappearing door handle. Some vehicles have completely eradicated the need for traditional door handles and now opt for a simple switch to open. For metalworking, this presents interesting development opportunities for suppliers like ourselves, to test the capabilities we have at our disposal to meet these market demands.

As interior trim components become larger, such as those in the Cadillac Celestiq, design engineers are embedding additional functionality within these pieces. As a supplier, we have to consider how a single sheet of formed metal can seamlessly incorporate these developments, such as switch apertures, into the final product, whilst maintaining a blemish-free A-surface.

Beyond this, we are also seeing more demand for parts that transmit lighting into the cabin. While ambient lighting isn’t anything new, being able to incorporate lighting through precision-etched metal trim is something we expect more OEMs to be introducing across the market in the near future. 

For vehicle manufacturers, we can offer their customers something new and completely different. At Vestatec, we work closely with brands to ensure they are well informed of the cutting-edge technologies and best practices that are available which can ultimately help them bring their visions to life.

What metalwork options do automotive engineers have, and how can Vestatec help these engineers determine the best for their projects?

Bylina: Automotive design engineers have a variety of metalworking techniques to choose from when creating premium interior trim components. These techniques include etching, stamping, casting, forging, and laser cutting, among others. These processes allow for the production of components ranging from small elements like tweeter covers to large pieces, such as full-width door panels.

Beyond metal forming, coatings are crucial for offering a range of color options to meet customer preferences. Commonly used coatings in the industry include painting, anodizing, and PVD—each providing distinct advantages for aesthetic and functional applications.

When discussing these options with our customers, we offer consultancy throughout to ensure they’re aware of the benefits of each and provide them with the information they need to make the right decision for their vehicle.

This is a flat chemically etched blank being positioned for pressing in the tool. VESTATEC

What metalwork processes does Vestatec offer to help automotive design engineers?

Bylina: Our core processes of metal forming, photo etching, PVD coating, and assembly offer our customers a premium solution to more traditional alternatives such as stamping and painting, which we believe is the key to creating high-end, luxury products for the automotive market. 

With photo etching, design engineers are able to work with a variety of aesthetic choices, such as intricate hole patterns or half-etched metal features. With half etching, it is possible to incorporate a debossed logo within the metal component. When combined with dark PVD, this process creates an eye-catching contrast. These capabilities mean OEMs and associated businesses such as audio system manufacturers can subtly incorporate their brand within the vehicle’s interior. 

We’ve also invested heavily in our own on-site PVD chamber to meet the demand we are seeing for more-sustainable coating solutions. Our process uses an electric arc to vaporize a metal target within a vacuum. The plasma this creates is then combined with a tailored recipe of gases to create a colored compound, which is deposited atom by atom onto the substrate, forming a highly adhesive, strong, and thin coating. PVD allows us to offer durable, high-quality, and aesthetically pleasing coatings in a variety of colors—including black, silver, gold, blue, and many others.

At Vestatec, we pride ourselves on being willing to push the boundaries of what can be achieved. Our experience and expertise in metal forming has enabled us to deliver the most complex, multi-stage pressed parts on the market. We are also market leaders in the use of photo etching and PVD coating, the combination of which allows us to deliver unique solutions that stand out as decorative features, even in the most luxurious cabin. 

Are plastic materials presenting competitive options, and if so, how could metal remain an appealing option?

Bylina: When up against metal alternatives, plastic often serves a crucial purpose in highlighting the value of metal components; without it, the premium nature of metal would not be as pronounced. And, while plastic offers a cheaper alternative to metal, it cannot match the premium feel you get with aluminum or steel. Moreover, when combined with PVD coating, metal offers a more environmentally friendly solution as it is 100% recyclable at ‘end of life’, unlike plastic, which poses environmental challenges. 

However, it is also true that not all metal components available in the market today offer the level of luxury and quality our customers expect. For example, some vehicle manufacturers use pre-perforated speaker grilles as a step up from plastic. Whilst these components offer the ‘cold touch’ of metal, the choice of hole patterns is very limited compared to photo etching, which allows almost unlimited design freedom.   

Away from metals and plastics, there are other materials that could be combined with premium metal to elevate vehicle interiors, such as wood and leather—both of which play a crucial role in differentiating the cabin. Not only do they complement each other, with metal adding value and sophistication to the overall design, but they offer a personalized aesthetic that premium vehicle buyers opt for when choosing the right car for them.

How do engineers begin their metalwork designs and where do they go from there?

Bylina: The metalwork design for automotive interiors begins with conceptualizing shapes and patterns that complement the vehicle's style and interior aesthetics. This concept should be refined through engineering to meet industry standards and functional needs. 

Partnering with Vestatec early on allows automotive engineers to leverage our expertise in crafting innovative, high-quality metal component designs that enhance the vehicle interior. Vestatec leads the way in metalworking in the automotive sector, delivering pioneering solutions that drive the evolution of interior design.

Our comprehensive processes and collaborative approach empower engineers to create visually striking, robust, and durable interiors that meet the dynamic demands of the automotive market. Our commitment to excellence, sustainability, and innovation sets new benchmarks for quality and design in automotive interiors.