Edited by Dianna Brodine, vice president, editorial, Plastics Decorating
For more than 35 years, the Ford Explorer has been a steady contributor to the midsized SUV segment with a variety of trim levels, third-row family seating and a name that appeals to the adventurer. The 2025 model year received an upgrade in both style and safety with a film-insert molded applique that showcased decorative graphics and functional lighting in a single, lightweight component. It caught the eyes of the judges in the 2025 IMDA Awards Competition, winning in the category of Best Use of In-Mold Decorating for a High-Complexity Application.
Produced for Ford Motor Company, the part was molded by OPmobility (Troy, Michigan). Advanced Decorative Systems (Millington, Michigan) acted as the label printer, with the label substrate provided by Covestro LLC (Pittsburgh, Pennsylvania).
IMD Offers Aesthetics, Durability
Automotive design is constricted by factors that include overall vehicle weight, a limited interior space, and interior and exterior durability requirements. In-mold decorating (IMD), according to Covestro, offered the ideal combination of aesthetic freedom, component consolidation and environmental durability.
The graphics for the rear taillight application are encapsulated within the molded part, protecting them from abrasion, UV and chemical exposure. Tight graphic registration and complex surface forming enabled the desired visual clarity, even on curved surfaces. Backlighting was embedded directly behind the IMD layer, eliminating the need for separate light guides or bezels, and a custom diffuser pattern was engineered within the printed film layers to ensure even illumination, avoiding hot spots or light bleed. The result was a striking visual element that enhanced the overall vehicle design.
Production was just as impressive. Film insert molding allowed the manufacturing team to combine decoration and structure in a single, ultra-thin part, reducing bulk and weight. Maintaining crisp details and consistent surface finish across compound curves required tooling innovations and advanced film registration controls. The thin, flexible film insert posed handling challenges during molding, which were resolved using automated placement fixtures and controlled heating profiles.
Successful execution of a functional component under the minimum required thickness demanded careful coordination between film selection, LED integration and mold design.
“This project shows what’s possible when material suppliers, printing experts and mold engineers collaborate early in the development process. We were able to meet demanding optical, formability and durability requirements within an extremely tight thickness envelope because of strong partnerships across the supply chain,” said Joe Staniszewski, mobility segment manager, Specialty Films, Covestro LLC.
Consumer and Customer Reaction
As automakers continue to seek innovative ways to elevate design while improving manufacturing efficiency, the award-winning Ford Explorer applique demonstrates the growing potential of in-mold decorating technology. By combining striking aesthetics, integrated lighting, durability and lightweight construction into a single component, Covestro, OPmobility and Advanced Decorative Systems delivered a solution that meets both consumer expectations and production demands.
The part contributed to weight savings and assembly simplification in the rear module, supporting Ford’s manufacturing efficiency goals. Consumers have responded positively to the premium look and feel, with the illuminated applique using light to replace traditional chroming – cited in the press as a standout design and environmentally friendly detail. The solution is cost-effective compared to traditional multi-part assemblies, reducing tooling and labor costs while offering high-volume scalability.
This applique uses IMD technology to enable elegant design, manufacturability and brand identity, all within the practical constraints of today’s automotive exteriors. The IMDA Award recognition underscores how advanced decoration technologies are helping shape the next generation of automotive design – where form, function and sustainability work seamlessly together.