Used for exterior vehicle branding requiring corrosion resistance and stable outdoor performance
This case shows how Himgo supported a German automotive supplier in resolving corrosion and coating instability issues in outdoor vehicle emblems, achieving stable performance under salt exposure, UV conditions, and temperature variation.
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Project Overview
Industry: Automotive
Location: Germany
Customer Type: Tier 2 automotive component supplier Product: Zinc Alloy 3D Metal Emblem
Application: SUV / Pickup tailgate badge Size: 85 × 28 mm
Thickness: 2.5 mm
Relief Height: 1.2 mm Mounting: Adhesive (3M VHB) Lead Time: ~6 weeks
MOQ Range: 100–500 pcs
Application Scenario
The emblem is installed on vehicle tailgates and exposed to continuous outdoor conditions.
Key environmental factors include:
- Road salt exposure during winter
- UV exposure under European climate
- Temperature variation from -20°C to 60°C
- Rain, humidity, and moisture cycles
- High-pressure washing with detergents
This combination creates long-term corrosion risk and surface degradation challenges.
Customer Problem
The customer replaced their previous supplier after experiencing:
- Corrosion appearing after 3–4 months
- Black coating fading under UV exposure
- Color inconsistency between batches
- Adhesive detachment during winter
These issues affected both durability and brand appearance consistency.
Engineering Challenges
The project required resolving multiple linked issues:
- Preventing corrosion under salt exposure
- Maintaining coating stability under UV
- Controlling color consistency across batches
- Ensuring adhesive performance at low temperatures
- Avoiding die casting surface defects
Material & Process Decision
Material Selection: Zinc Alloy (Zamak)
Use when:
- A true 3D emblem structure is required
- Relief detail must remain consistent across production
- Automotive exterior use requires dimensional stability
Zinc alloy enables stable die casting and consistent geometry.
Manufacturing Process: Die Casting
Use when:
- Relief height above 0.5 mm is required
- Structural consistency is needed across batches
The selected process achieved a 1.2 mm relief height with controlled tolerance.
Surface Treatment: Nickel Electroplating (10–15 μm)
Use when:
- Corrosion resistance is required for outdoor environments
- Surface durability must be improved
This layer supports resistance to salt exposure.
Black Area Treatment: UV-Resistant Coating
Use when:
- Color stability must be maintained under UV exposure
Adhesive System: 3M VHB (0.8 mm)
Use when:
- Mounting is required on painted surfaces
- Adhesion must remain stable under temperature variation
Key Manufacturing Parameters
- Relief Height: 1.2 mm
- Dimensional Tolerance: ±0.15 mm
- Electroplating Thickness: 10–15 μm
- Adhesive Thickness: 0.8 mm
- Salt Spray Resistance: 500 hours (ASTM B117)
Production capacity reference: 500,000+ pcs/month
Testing & Validation
Testing conducted to verify performance:
- Salt spray testing (ASTM B117)
- UV aging test
- Coating adhesion test
- Adhesive peel strength test
- 100% visual inspection
ASTM B117 defines the testing environment for corrosion resistance comparison.
Results
The final solution achieved:
- Passed 500-hour ASTM B117 salt spray test
- Color variation controlled within ΔE < 1.5
- Yield rate above 98.5%
- Adhesion stable at -20°C conditions
- No corrosion or detachment reported after 6 months field use
When to Use This Solution
Use this solution if:
- The product is exposed to outdoor automotive conditions
- Corrosion resistance under salt exposure is required
- Batch color consistency is critical
- Adhesive mounting must perform under temperature variation
Related Solutions
- Custom Metal Emblems
- Zinc Alloy Die Casting
- Automotive Industry Applications
