GRAPHIC OVERLAYS

 

Benefit from graphic overlays that offer the most durable option of non-metallic labels. Our clients choose this material for its quality, appearance, and durability.

We make graphic overlays using screen, digital and offset printing, windows, cutouts, and finishes suitable for every environmental requirement.

American Graphic Overlay Manufacturer with Decades of Experience

A graphic overlay is the top layer of a membrane switch that works as the interface between users and machines. It ensures the application’s durability and protects it against scratches, chemical abrasions, and extreme temperatures. 

Develop a custom graphic solution for your products with our experts. Take advantage of full customization and personalization to develop graphic overlays for the most demanding environments.

Certified graphic overlay manufacturer

Melrose is a prominent graphic overlay, membrane switch and keypad producer in the United States, with decades of industry expertise. Melrose provides billions of machines and equipment with a touch of customization by following a unique engineering approach established over the years.

When it comes to developing and implementing user interface goals, customers rely on our experience and certification. We possess numerous certifications, ranging from AS9100D to ISO 9001:2015, providing exceptional value and assisting our customers in achieving compliance.

Our Services

Customization and Personalization

We create bespoke graphic overlays, membrane switches and keypads to guarantee that the finished product matches your exact needs. Our specialists make sure that every customer receives a tailored experience and a bespoke solution that matches their needs.

Starting with a high-quality prototype is the key to producing graphic overlays for membrane switches. You will get a prototype that matches the product specs at the start of our partnership. We also ensure that our engineers adhere to all safety and quality requirements.

About graphic overlays

Graphic overlays can be found on electrical equipment where they serve as front panels. They’re printed on the reverse of a transparent material and serve as the most lasting type of non-metallic label. The construction of graphic overlays protects the ink from wear and tear, providing excellent quality and value.

Graphic overlays are frequently designed in combination with a system’s buttons, touchscreens, LED backlights, and indicators. Our graphic overlays can be entirely opaque or feature transparent “dead front” pictures in the backlight. With epoxy keycaps, urethane silicone, materials, and embossing, we can elevate the look of any application. We can also add variable data, such as model numbers within a product family – all to make sure that the graphic overlay serves its purpose. 

Our team of specialists will assist you in selecting the most appropriate choice. We take into account the surface to which the overlay will be applied (surface texture and chemistry) and environmental factors such as UV exposure, salt spray, solvent, acidity, and temperature range.

We manufacture graphic overlays using proven materials

Polycarbonate is a popular material for both indoor and outdoor applications. Our polycarbonate overlays can come in different textures – from matte to coarse velvets – depending on the desired look. 

Since polycarbonate is relatively soft and may scratch easily, our experts treat it with a hard coat material. Hard coatings are available in various gloss levels, depending on your application’s requirement for glare attenuation. Polycarbonate comes in thicknesses ranging from .005” to .156” (and more).

Polyester is the go-to overlay material for membrane switches thanks to its high durability and excellent fatigue resistance. Polyester is available in textured, scratch-resistant glass and outdoor-rated options.

Our experts can deliver polyester overlays with scratch-resistant hard coats that are essential in clear window applications. Polyester overlays come in thicknesses of .008” and thinner.

At Melrose Systems, we have decades of experience in developing all kinds of graphic overlays. Apart from polycarbonate and polyester, we extend our offer to provide our customers with overlays made of acrylic and tempered glass.

The choice of adhesive for an overlay application depends on many factors:
  • Second surface printed ink on the overlay’s backside,
  • Surface to which the overlay will be attached,
  • Application environment,
  • Spacer stack-up needs.
Our experts can assist you in selecting the best adhesive for your specific use case.

We use innovative finishing techniques

Printing

We use screen, digital, and offset printing to apply images of all kinds to graphic overlays – including spot, metallic, or full-color images.

Die-cutting

Overlays and membrane switch layers that are thinner than .020″ are die-cut using steel rule dies, digital cutting methods, or class 1 die-sets. Our experts usually cut thicker parts using digital routing, laser cutting, or water jet cutting technologies.

Embossing

Embossing helps accentuate the critical area of a graphic overlay. We can emboss graphic overlays using a male/female die set. The features are typically raised .010″ (1.5x material thickness) if embossed – this can serve, for example, to raise LEDs above the overlay surface or provide a decorative effect to a logo or text.

Hydroforming

An alternative to embossing, hydroforming involves more expensive tooling, set-up, and cycle times. It allows adding feature heights up to three times the material thickness.

LCD windows

Graphic overlays often feature clear windows for viewing LCDs. Such overlays with LCD windows are manufactured using glass, hard-coated and scratch-resistant polyester, or polycarbonate. The LCD windows can be specified with alternative gloss levels for glare attenuation requirements or a window tint, selecting appropriate background colors.

LED windows

Our experts can develop graphic overlays with small, clear, and round windows for viewing light-emitting diodes (LEDs). The windows can be flush with the overlay surface or embossed so that LEDs are raised above the overlay surface. Such LED windows can be tinted or dead fronted.

Take the first step in designing your graphic overlay

How to design a graphic overlay and make sure that it meets the needs of your application? Use our free design guide to get started. Once you go through it, you’ll be able to design your graphic overlay. 
Our guide will walk you through the following points:
  • Substrates used for graphic overlays
  • Durability requirements
  • Testing the surface affection
  • Lenses and gaskets
  • Design techniques
  •  

If you’re not sure whether you’re making the right choices, get in touch with us. One of our dedicated advisors will gladly help you out and design a perfect membrane switch with you. 

When Achievements Talk Better Than Promises

Fast shipping

We keep a permanent stock of basic products. That’s how we’re always ready to meet the needs of our customers. No long waiting times, no delays. The Melrose team is always there to make sure your company is ahead of the game.

Tailor-made solutions

Whatever feature combination you need, we can deliver it to you. Create your product by choosing various parameters. Get in touch with us, and we will start the customization process within 24h of receiving your order.

Modularity

Thanks to our unique modular system, we can offer the same display size in different configurations and adapt it to any project by easily upgrading the display without changing the product design.

The Melrose World:

Sharing our expertise about membrane switches and keypads is our passion. Discover more engineering insights and learn from our experts.

Designing custom prototypes doesn't need to be expensive and time-consuming.

Talk with the Melrose engineers to layout a prototype you wanted to launch. Get your customized product with a 100% satisfaction rate.

Melrose has superior knowledge in using the right technology, meeting every requirement consideration. Call us for any clarification.

Get Custom Membrane Switch/Keypad Prototype Design That Matches Your System