FAQs

We don’t have a minimum order quantity; we can make as few or as many items as you require. However, the more pieces we can make at one time, the better the unit price.  Small print runs are expensive to set up, especially if new and/or complex artwork preparation is required.

We can work with any graphics file – even a hand drawn sketch! But there are some things to consider when supplying your artwork to us.

Vector Files

We prefer files to be supplied in vector format.  Vector files hold their colour information in a way that not only specifies the colour at a particular point, but how the colour is changing in all directions.  This feature means vector graphics can be scaled to any size without loss of quality. We use Adobe Illustrator for artwork and prepress, so if you can supply Illustrator (.ai) files, this is best.  Other vector formats such as .svg or .eps are also OK.

Pixel (bitmap, raster) Files

Common graphics formats such as JPEG, TIFF, PNG, GIF and BMP are pixelated files, where the colour at each point is represented by a single pixel.  Pixel files are created by digital cameras, or simple graphic software like Microsoft Paint.

Pixel files can’t be enlarged without significant loss of quality. The more pixels in the file, the more detail it will contain and the better the result when it’s printed.  A high resolution camera photo will print well, but a low resolution photo clipped from a web page will not.

If you only have JPEG, TIFF, PNG, GIF or BMP files we usually recreate them in a vector-based format to deliver a good print result.

CAD Files

We also use CAD files, such as DXF or DWG. CAD software and Graphics software have evolved in two different ecosystems and there are significant cross-compatibility issues between them. Please give us a call to discuss this.

Yes.  Variable data like a unique serial number or production tracking number can be added to any print.  Generally, variable data is better placed on a dedicated serial number label, rather than integrated into the print of a key pad or control panel.    Give us a call if you’d like advice or suggestions on the best approach.  Our expert team is happy to help.

Digital printing is easy to setup and change.  Initial prototypes and small production runs are usually made using digital printing processes. Screen printing is the preferred process when manufacturing electronic keypads and control panel graphic overlays in larger production volumes.

Screen printing is fast and delivers very high quality but it cannot match the colour flexibility of digital processes.  Each screen printed colour is printed one at a time, which requires a new setup up for each pass. Therefore, the more colours contained in the artwork, the more passes through the process.  This increases cost.

These issues can be minimised by making sure you plan your artwork so that it can be easily scaled to larger volume production process.  This means using single spot colours and avoiding gradient colours. This minimises the number of colours and hence process passes.  Give us a call if you’d like advice or suggestions on the best approach.  Our expert team is happy to help.

Yes.  Digital UV printing is flexible and easy to setup and change.  Initial prototypes and small production runs are usually made using digital printing processes, usually with a laser cut adhesive backer.

We can also produce a mock-up of the final overlay using low-cost laminated graphics. This is a good way to determine if you are happy with the layout and if the cut outs are positioned correctly.

Our labels are all custom made to meet your requirements, so we can make them any size up. There are some maximum size restrictions, so give us a call for more details on sizing.

But to give you an idea of how big we can go, we’ve produced control panel graphic overlays for industrial applications as big as 645 x 365 mm. For direct product printing, we commonly print up to 800 x 800 mm, and can go bigger than this if need be.  Digital flat sheet printing and laser cutting / etching is 600 x 400 mm maximum print area.  And digital self adhesive vinyl is typically 1200 x 1200mm.

At the other end of the scale, we produce serial number labels and similar products at a size of 20 x 10 mm, with very finely detailed text and bar codes.

Almost anything is possible, so give us a call to find out more.

Each keypad or control panel is custom designed for a specific application. There are two pieces of tooling that may be required:

Embossing Block

If your control panel graphic overlay or keypad requires raised or embossed buttons, we will manufacture an embossing block. The block consists of a matching pair (male and female halves) of formed magnesium. Embossing is the process of pressing the overlay or keypad film between the blocks.  A flat keypad can be used as an alternative: this has some advantages in that it is cheaper and easier to clean.  But embossing provides a better user feel on the product and is preferred by many designers.

Die Cutting Forme

A die-forme is like a cookie cutter, though more accurate and a lot sharper. We use this tool to cut the overlay or keypad once it’s printed.  Laser cutting can be used as an alternative if the volume is smaller.  But die cutting is a better choice if the volume increases.

We set up these embossing and die tools once at the very start of the job. We then store them for future runs of the same work.

Our keypads and control panel graphic overlays are made using two types of high-quality printing film; polycarbonate (Lexan) or polyester (Autotype). Each material has unique properties, and it is important to choose the one best suited to your application.

Polycarbonate

Developed in the 1950s, polycarbonate is a thermoplastic that has been used in a wide range of products, from fighter aircraft canopies to space suit helmets.  In the form of a thin flexible sheet, it is ideal for making control panel graphic overlays.

Made up of long polymer chains polycarbonate is an ideal material for simpler control panel overlays because of it’s exceptional impact and scratch resistance. And when it’s combined with a high-quality adhesive, you get a robust and very cost effective solution that will withstand harsh conditions over time.

Polycarbonate films commonly used for control panel graphic overlay production range from around 150-micron to 500-micron thick (0.15mm to 0.5mm), with both matte and gloss surface finish options.

Polyester

Polyester is strong, flexible and resistant to common chemicals. It’s also an excellent electrical insulator with a very high dielectric strength and resistivity, perfect for high-quality electronic keypads and control panel graphic overlays.

Polyester’s durability and flexibility are a result of its biaxially orientated film. This means that the polymer chains in the material are aligned in perpendicular directions, which dramatically increases the strength of the film. It has a superior ability to cope with flexing, making it ideal for embossed keypads and overlays which are subject to repetitive use and repeated mechanical flexing.

Polyester is resistant to almost all common chemicals and is only susceptible to damage from strong acids.

Polyester is significantly more expensive as a base material than polycarbonate, but does provide some characteristics that polycarbonate can’t match.   In summary, for best results it is essential to understand and match the material characteristics of the application you intend.  Call us to discuss and we’re happy to talk though your options in detail.