Techprint’s custom graphic overlays enhance the usability and visual appeal of electronic products across a broad range of industries, helping to convey branding and identify essential information on how to operate equipment. Acting as the primary interface between technology and users, graphic overlays also offer protection for industrial machinery, consumer gadgets, electronics, medical devices, and control panels.
Our Graphic Overlay Materials
We design and build custom graphic overlays from the following durable materials to achieve the perfect blend of functionality, aesthetics, and brand appeal.
Polycarbonate
Polycarbonate is the preferred material option for custom graphic overlays featuring:
- Dimensional stability
- Impact resistance
- Scratch resistance
In addition, polycarbonate’s optical clarity benefits backlit and display applications.
Polyester
Polyester (PET) is typically the first or top layer of a membrane switch and is ideal for embossed buttons, offering:
- Chemical resistance
- Durability
- Excellent protection
- Compatibility with indoor and outdoor use
The versatile material features reverse or surface printing capabilities for added protection and greater design longevity.
Design and Artwork Preparation
At Techprint, we finalize and approve graphic overlay designs before production begins. The design and pre-production stage of the printing process sets a baseline for a successful project and contains the following elements:
- High-precision graphics. We use vector graphics software (AutoCAD and Adobe Illustrator) to create high-quality icons, text, and logos and AutoCAD for mechanical precision/li>
- Cutout areas. Our team meticulously pre-plans display cutouts, window openings, and button holes for accurate placement.
- Tactile feedback areas. For keypads or membrane switches, we identify areas that require debossing or embossing.
Printing
Graphic overlay printing involves the transfer of text, designs, and graphics onto a chosen material. We follow these printing methods and processes to create custom graphic overlays that are durable and aesthetically pleasing:
- Ink selection. Based on the desired color vibrancy, adhesion properties, environmental resistance, and overall durability.
- Digital printing. A precise printing technique that employs inkjet technology to print high-resolution graphics onto a chosen substrate with quick turnarounds.
- Screen printing. A conventional method that pushes ink onto a substrate through a mesh screen. The technique is best suited for creating large areas of solid text and colors.
- Ink curing. Inks used in printing require an ultraviolet (UV) or heat-curing process that fully sets the ink to the substrate.
Adhesive Backing
We consider these factors for effective bonding of custom graphic overlays:
- Adhesive selection. Acrylic-based and pressure-sensitive adhesives used with graphic overlays must meet the bond strength, environmental, and adhesion requirements of the application. 3M adhesives (such as 3M467MP and VHB series) are the go-to choice in applications that require high-performance adhesion.
- Application methods. Adhesives can be applied using automated machinery for high-volume runs or manually with precision tools for smaller projects.
- Lamination process. Adhesives are applied via a single-layer process or to a spacer layer that is laminated to the back of the graphic overlay. Multiple layers can add another adhesive or structural layer.
Die Cutting
After the adhesive is applied, we cut the graphic overlay to the final desired shape. This essential stage of the process creates accurate dimensions and custom cutouts for displays, indicator lights, buttons, and more.
Our Die Cutting Methods
Our cutting processes maintain tight tolerances and high accuracy so that the final dimensions align with the overall functionality and design requirements of the product:
- Laser. Used in shorter production runs to create complex shapes and precision cuts.
- Rotary. Utilizes rotary dies to create intricate designs for high-volume production runs.
- Steel rule. A cost-effective technique that utilizes custom dies for medium to large production runs.
After cutting, we remove any excess material to reveal the final product.
Final Inspection and Quality Control
Once the cutting process is complete, we carefully inspect the cut pieces to ensure all cutouts have accurate dimensions and proper alignment. Comprehensive quality control involves the following processes:
- Adhesion testing. Verifies the adhesive is free from lifting or peeling and has the necessary strength for the specific application.
- Environmental testing. Simulates extreme temperatures, chemical exposure, and humidity to verify durability.
- Functional testing. Ensures the product performs as intended with an appropriate tactile feel.
- Visual inspection. Identifies any alignment issues, embossing imperfections, ink smudging, or other defects.
Custom Graphic Overlays at Techprint, Inc.
Since 1974, Techprint, Inc. has provided custom graphic overlays for a broad range of industries, with products that include printed electronics, labels, membrane switches, and more. Whether you need a nameplate that identifies your brand or a custom graphic overlay for an electronic system, Techprint has the capabilities to design, print, and manufacture it for you from start to finish.
Our experienced design team draws on vast expertise to create graphic overlays that match your exact specifications for brand identity, environmental usage, and product requirements. We produce graphic overlays under an ISO 9001:2015-certified quality management system and carry certifications from UL and CSA.
Contact us today to learn more about our graphic overlay design and printing capabilities.