Graphic Overlay: Introduction and Choices for Membrane Switches

What holds more significance for you among substance and style? When it comes to membrane switches, answering this question could be a little tricky.  As for a graphic overlay, you would have to consider both qualities at the same time. In this article, we will discuss why this membrane switch component is the real deal.

Graphic Overlay: Design Considerations

The upper layer of the membrane switch is a graphic overlay known as a faceplate. It is also known as membrane switch overlay. A well-designed membrane switch overlay improves the interface appearance. It also offers a few other benefits, such as improved user experience and easy operation.

You can have these overlays intricate or basic according to your need. Here are the available design considerations to set the final product and membrane switch overlay apart:

1. Graphics and Branding

In simple words, the overlay graphics is the place where you see the printed feature of a membrane switch. In addition, the membrane switch overlay can be a photo-like graphic quality overlay with digital or screen printing methods. You can also design different graphics to create indicators, instructions, and texts, etc. You can also create decorations and branding, callouts, key shapes, and buttons. Apart from that, graphics are designed for creating backgrounds or gradients to match device surfaces.

2. Coatings and Textures

You can enhance the appearance, durability, and usability of the product by adding different coatings and finishes. However, it depends on the environment as well as the product itself. Thus, it includes gloss or texture finishes, hard coating for UV or scratch resistance, and anti-bacterial films for healthcare environments. You can also create laminates for protection against chemicals and liquids, etc.

3. Embossing

This is a conversion process that utilizes special equipment for raising particular places of a graphic overlay. There are a couple of common embossing methods for membrane switches. The two techniques are:

Pillow Emboss: This technique is utilized for creating a button or key. The button or key is created with the tactile feedback under the elevated area.

Rim Emboss: This technique is used for decorative tasks, like making a printed logo border.

4. Cutouts and Windows

These are the two conversion methods for achieving a customized membrane switch. The window is specifically utilized for viewing indicator lights, LEDs, LCD, or some functional features. A transparent or clear lens or material is placed in the display area for internal components protection.

Also, the cutout is the hole in the membrane overlay. Generally, it accommodates hardware, such as mounting screws, lens, and displays, etc.

Creating an optimal membrane switch overlay requires both production capabilities and engineering knowledge. Also, a reputable manufacturer should have the required experience to convert any graphic overlay concept to reality.

Environmental Considerations

Here are the environmental considerations that affect membrane switch overlay design and material choice:

1. Indoor and Outdoor Use

Humidity, moisture, extreme temperatures, and UV all can degrade and reduce the life of a membrane switch. Therefore, you should ask experts for their recommendations about the overlay material. The overlay material must resist these conditions.

2. Abrasion and Chemicals

Cleaning agents and/or industrial chemicals can affect the material of graphic overlay. So, you must choose the material very carefully that can resist these chemicals.

3. Sterile Environments

You may need an anti-bacterial overlay material that obstructs microbial growth under sterile environments. It is also important to make sure that the material bears severe cleaning agents.

4. Environment Lighting

Some natural and artificial lights may cause glare. This glare makes the membrane switch overlay hard to interpret, making it difficult for the eyes. It is important to make sure that the material is in the range of antiglare and gloss levels. This will improve the membrane overlay readability.

5. Heavy Use

In environments where the operator use is heavy or even there is abuse, it becomes essential to specify an overlay material that easily resists such misuse. Rather than using an ordinary .007 thickness overlay, you should use a robust overlay material. The ideal overlay materials, in that case, can be:

• .060 acrylic
• .020 metal-photo anodized aluminum
• .040 glass
• .018 stainless steel

Special technologies are available that can make these overlays more rigid for appropriately actuating the keypad of the switch. You can talk to the experts for detailed information about such technologies.

Aesthetics Considerations

Here are the aesthetics considerations that can affect the overlay design and material choice:

1. Surface Finish

A graphic overlay’s surface finish is a function of screen printing and material type. The finishes include non-glare, patterned, glossy, and textured. There are also some metal finishes available, such as stainless steel and brushed aluminum.

2. Printing Effects

Apart from screen printing, the switch overlays can also be printed with digital processes. Because of that, the overlay graphic can use creative effects, including gradients, fades, photo-quality images, and customized spot colors. Therefore, you also have the luxury of special printing effects.

3. Limitless Color Choices

The best part is that you can use any color range to print graphic overlays. The color range includes a number of colors such as metallic gold, metallic silver, bronze, and copper, etc. You can also combine the finishes like the brushed surface with metallic colors. Doing this will encourage the brushed metal look. Therefore, you have the choice to select from a lot of color choices.

4. Back Lighting & Displays

Generally, most of the membrane overlay switch materials are clear or transparent. Moreover, you can incorporate back the display and lighting components. The available lighting options are LED lamps, LCD, fiber optics lamps, and EL lighting, etc. It is essential to specify the overlay material type that improves the desired effect of backlighting.

5. Embossing

You can also emboss the overlays, which the second operation to elevate the overlay at chosen areas, usually the keypads. The embossing styles include pillow-embossed and perimeter embossed. You can emboss the symbols like lettering if you want a decorative look. Moreover, embossing is an ideal option when you need to accentuate logos and brands. It is also important to know that there will be stress on the material with embossing which reduces the flex lifespan of the keypads.

Processes

The graphic overlay processes involve die cutting, embossing, laminating, forming, machining, serial stamping, and bar codes. Thus, the product can be cut into rounded corners, unusual shapes, hard dies (metal parts), steel rule dies (flexible materials), and thermal dies (vinyl substrate), etc. With embossing, you can also add three printing dimensions for specific identification.

Laminating process protects the overlays, decals, and printed nameplates. Forming is carried out for blending as per your specifications. Therefore, you can manufacture any square, round, or rectangular metal nameplate, control panel, or serial/VIN plate without extra tooling charge with machining.

Serial, model numbers or VIN is stamped on metal or flexible substrates with serial stamping. It is also possible to print bar codes on any VIN/serial plate, nameplate, graphic overlay, control panel, or other surface types.

Graphic Overlay: Take Away

The rightly designed graphic overlays are a great tool to set a great first impression about your equipment and your company. It is the switch overlay design that makes the equipment stand out from the rest by ensuring an unparalleled user experience.

It doesn’t only represent the equipment operation, but it also satisfies the aesthetic needs. More importantly, it satisfies the needs of physical and environmental end-use applications.

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