CUTTING MACHINES FOR SCREEN PRINTING MEMBRANE SWITCHES

One of the most crucial aspects of manufacturing membrane switches is the cutting process. Cutting machines used for membrane switches play a significant role in ensuring precision, speed and the overall quality of the final product.

As a rule, membrane keyboards are made up of several individual layers. These layers are placed on top of one another and constitute the overall structure of the control elements. The top layer is called the overlay and is very often made of polycarbonate or polyester. The rear side of the foil is printed, in order to ensure the best possible protection against abrasion.

The typical application used here is silkscreen printing. Although, a sharp rise in the use of digital printing is now being seen in this industrial segment, due to the need for flexibility. The design and functionality of these switches make them suitable for applications where durability, space efficiency and ease of cleaning are essential.

One of the best known screen-printed materials is polycarbonate. Polycarbonate is a type of plastic that is naturally transparent and lightweight. It stands out for its remarkable longevity. This is because it is technically unbreakable and tougher than other clear-sheet materials with similar thicknesses. It is for this reason that polycarbonate is a common option for making printed signage. Membrane switches do not generally exceed 1mm in thickness. Their rigidity varies according to the layers and adhesive used.

Layer alignment – Membrane switches consist of multiple layers, including conductive layers, adhesive and graphic overlays. Misalignment during cutting can lead to faulty switches.

Thickness control –Different layers of the membrane switch vary in thickness. It is important that the cutting machine can handle these variations without compromising the integrity of the materials.

Edge quality – Clean, smooth edges are necessary for both aesthetic and functional reasons. Rough or jagged edges can lead to wear and tear, reducing the lifespan of the switch and negatively impacting the user experience.

There are few devices to cut this plastic material – including rotary and laser cutters – but the change to flatbed-cutting machines is getting more and more popular. Some may use a roll-to-roll cutter, but this type of operation very often only cuts the film top-layer, leaving the backing material intact. For more resistant materials, the ideal option is the flatbed cutter.

The change to flatbed-cutting machines is getting more and more popular

A flatbed-cutting machine uses a stationary blade that moves in a straight line to cut through the material. The material is typically placed on a flat surface while the blade moves to cut shapes.

Flatbed-cutting machines are versatile and can handle a wide range of materials, from flexible films to rigid plastics. They also allow for the cutting of larger sheets of material in a single pass.

Most industrial products today cannot be standardised and require customised shapes. They are rarely square, rectangular or circular and, for this reason, shapes cannot be predefined. A digital-cutting machine can cut any customised shape.

Flatbed-cutting machines offer a dual option thanks to their modular holders. One tool can be used to cut through the material (especially rigid ones), while another can be used for kiss cutting. This method peels off the top layer without damaging the back side.

When selecting a cutting machine for membrane switches, several factors must be taken into consideration. This is to ensure that the equipment meets the specific needs of the production process.

Material compatibility – The cutting machine must be capable of handling the materials used in membrane switches, such as polyester, polycarbonate and adhesive-backed films. Some machines are better suited to thinner materials, while others can handle thicker substrates or multi-layered constructions.

Cutting precision – The level of precision required depends on the complexity of the design. Laser cutters, for example, provide the highest degree of accuracy, while die-cutting machines can handle intricate designs with great consistency.

Speed and efficiency balance – High-speed cutting machines can significantly improve throughput in high-volume production runs. It is important to balance speed with precision to ensure that quality is not sacrificed for faster production.

Cost effectiveness –While high-end cutting machines offer superior precision and versatility, they can come at a higher upfront cost. It is important to weigh the benefits of advanced technology against production volume and budget.

Automation and integration –Modern cutting machines often come equipped with automation features, such as automatic material feeding and cutting path adjustments, which can enhance efficiency. Additionally, seamless integration with other manufacturing equipment – including printing or lamination systems – can streamline the production process.

Milling option – This makes it possible to handle a wider range of materials. It can enable expansion of a business into new directions, to reach a wider customer base. Some flatbed cutters may house a one kilowatt router to mill typical media for the signage industry, such as aluminium composite di-bond, plexiglass and PVC.

Maintenance and support – Reliability and ease of maintenance of a cutting machine are critical factors. Regular maintenance ensures consistent performance. Furthermore, good customer support and training can help reduce downtime.

Flatbed-cutting machines are versatile and can handle a wide range of materials

The cutting process for membrane switches is essential to ensuring the final product meets high standards of precision, functionality and durability. Whether using die, laser, rotary or flatbed cutting, selecting the right cutting machine is key to achieving the desired results. Manufacturers need to carefully consider material compatibility, cutting precision, speed and cost when choosing the most appropriate machine for their production needs. As the demand for more advanced and custom membrane switch designs grows, cutting-machine technology continues to evolve. Developments and innovation in this field offer solutions to meet the challenges of modern production.