Manufacturing Process of Volvo’s Crystal Gear Shift Knobs

The impressive and attention-grabbing attributes of the crystal gear shifters in Volvo’s vehicles might surprise you – they are actually simpler to manufacture than some of the plastic parts in the cars. Designed to fit comfortably in the hand, these gear shifters are not merely decorative; they serve a functional purpose. While this feature itself is intriguing, what truly brings the story of the crystal gear shifter to life is the underlying philosophy. It all originates from the harsh, gloomy winters typical of Volvo’s home nation.

“The winters in Sweden are challenging,” explained Cecilia Stark, the head of Volvo’s color and materials division. “Given the darkness prevalent here, the presence of light is crucial.”

The allure of crystal lies in its internal play of light. Glass can exude a cold and sleek feel, reminiscent of ice. Alternatively, it can be sculpted into faceted shapes that allow beams of light to pass through, illuminating it from the inside. In a land where daylight hours in winter are limited to just four or five, the celebration of light seems logical. 

“In Sweden, our focus is on manipulating light and creating cozy atmospheres to the extent that we often forgo curtains,” Stark remarked during our telephone conversation. “Light serves as the focal point for everything. It holds significant importance for us, and consequently, we aim to instill a warm ambience within our vehicles as well.”

Having spent over two decades in Volvo’s textile division, Stark now oversees the strategic advancement of all color and material aspects in Volvo vehicles. She is dedicated to aiding Volvo in creating opulent yet environmentally conscious interiors, open to reconsidering any material used. Stark and her team are not bound by conventional methods and are continually exploring alternative textiles and materials. Just last autumn, Volvo declared the phasing out of leather usage.

“I am increasingly convinced that nature should serve as a wellspring of inspiration,” Stark emphasized. “We are presently investigating the potential of wool, linen, and other natural materials. Our aim is to transform the interior of our cars into a more homely space rather than a purely technical one.” 

The craftsmanship required to produce crystal is indeed unique, and Volvo has collaborated with Orrefors, a Swedish establishment with a tenure exceeding a century. Not just any crystal firm, Orrefors boasts a workforce of artisans crafting original hand-blown pieces. While undoubtedly more costly, Volvo believes the investment is justified. Stark reveals that some car manufacturers opt for pressed glass over genuine crystal, likening it to choosing Ikea’s particle board furniture over a meticulously crafted wooden piece.

It’s interesting to note that Volvo found that the tools Orrefors utilized for crystal were less intricate compared to the ones used by the car manufacturer for plastic components. This allowed the design team to create uncomplicated graphite molds for prototypes, which were then filled with molten glass at the Orrefors factory. As Volvo mentions, after the shifter is removed from its mold, it undergoes a heat treatment process to eliminate any imperfections on its surface. During this phase, the crystal gains a smooth texture. It is then placed in an oven to cool down gradually for almost an entire day to reduce any inherent stress within the crystal.

Upon completion, Volvo encloses it within a plastic frame and chrome finish. This additional cushioning is designed to absorb impact energy before it reaches the crystal.

To illuminate the gear shifter from within, an LED light was inserted into the plastic base, which is part of the electronic shift-by-wire system. This posed a challenge: the only method to affix crystal onto plastic is through adhesive, but Volvo’s designers wished to conceal the glue at the base. After evaluating 80 different adhesives, the company discovered one that was transparent and unaffected by the differing heat expansion rates between crystal and plastic. Furthermore, it did not obstruct the light source from the center of the gear shifter. 

I view it as a subtle tribute to its luxury classification. A single small crystal gear shifter is a delightful addition, much more appealing than extravagant displays of opulence like the Lamborghini Huracan adorned with 1.3 million Swarovski crystals. Even for a material reminiscent of ice, it exudes a strangely warm sensation, just as Volvo intended. 

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