Innovating Surface Decoration for Seamless Ceiling Integration
The Challenge
A leading manufacturer of mobile and prefabricated homes sought to improve the appearance of its drop ceiling systems by redesigning the divider components to blend seamlessly with the surrounding panels.
Applying a textured finish to a plastic extrusion presented a unique engineering challenge. Traditional embossing techniques could only create the illusion of texture through surface depressions—but not the true three-dimensional feel needed to match the ceiling panels. Additionally, the texture material itself required a surface formulation that allowed for strong adhesion and consistent coverage during continuous production.
Achieving a realistic, uniform texture inline—without secondary processing—required an entirely new approach.
The Solution
To solve the problem, Engineered Profiles went beyond conventional extrusion practices. A technical representative was sent directly to the original ceiling texture manufacturer to study the process and identify how it could be replicated for plastic components.
Innovation doesn't always mean new materials - sometimes its about new methods.
Inline processes can turn standard extrusions into standout designs.
Armed with those insights, our engineering team developed a custom inline spray texturing process—a first of its kind in this application. This innovation applied a true 3D texture directly to the extrusion during production, allowing the ceiling dividers to visually and physically match the surrounding panels.
The result was a seamless aesthetic, achieved through a controlled, repeatable process that maintained quality standards at full production speed.
The Result
Engineered Profiles’ solution produced a fully integrated decorative profile that met the customer’s design vision and manufacturing requirements. The new texturing process eliminated the need for post-production finishing, reduced costs, and provided a unique surface treatment technology that elevated the visual quality of prefabricated interiors.
This project exemplified how Engineered Profiles blends engineering expertise, creativity, and collaboration to solve complex material and aesthetic challenges.
