What is subsurface printing and why do control panels use it?

Subsurface printing puts the ink on the back face of a clear substrate, so the material itself sits between the graphics and the operator. Abrasion never touches the ink, which is why a subsurface-printed Lexan panel stays legible after a hundred thousand actuations while a face-printed one wears through.

Lexan or Mylar — which should I specify?

Lexan where the graphics have to survive heavy actuation or need deadfront windows, because it is printed subsurface and the substrate protects the ink. Mylar where you want a metallic finish — brushed, matte or bright silver — and the wear profile is lighter. Both come in 5 to 20 mil and both can be die cut and embossed.

What is a deadfront window?

A deadfront window is an area of a Lexan panel printed so it reads as solid panel until the display behind it is backlit, at which point the indicator or readout appears. It keeps a control face clean when the machine is idle.

Can I get a prototype before committing to a production run?

Yes. We produce a physical prototype for fit verification against your panel and switch assembly before the run is manufactured, and prototyping is also available as a standalone service for engineering validation.

Stacked rolls of white service labels, each carrying a barcode, a unique alphanumeric asset code and bilingual service instructions

Products · Graphic overlays

Custom Graphic Overlays and Control Panel Faces

A graphic overlay is the interface between a machine and the person operating it. It has to stay legible after a hundred thousand actuations, resist the cleaning chemicals used around it, and register precisely with the switch assembly underneath. Printing it is straightforward. Building it so the graphics never wear off is not.

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CSC ServiceWorks · Serialised asset labels

Airmark manufactures overlays in clear polycarbonate (Lexan) and opaque polyester (Mylar), both available in 5 mil to 20 mil thicknesses.

Subsurface printed

Lexan overlays

Lexan overlays are printed subsurface — the ink sits on the back face of the material, so the substrate itself protects the graphics and abrasion never touches them. They can be laminated with 2 mil or 4 mil custom 3M adhesive depending on the specification, and Lexan is available for exterior applications as well.

Lexan can also be printed with deadfront windows, so display areas read as solid panel until backlit.

Material: Clear polycarbonate (Lexan)
Thickness: 5 mil to 20 mil
Print method: Subsurface — ink on the back face
Adhesive: 2 mil or 4 mil custom 3M
Exterior grades: Available

Face printed

Mylar overlays

Mylar overlays are printed face up and laminated with a clear protective film. Mylar is available in brushed silver, matte silver and bright silver finishes, along with other colors and textures.

Material: Opaque polyester (Mylar)
Thickness: 5 mil to 20 mil
Print method: Face up, laminated with clear protective film
Finishes: Brushed silver · matte silver · bright silver

Finishing

Die cutting and embossing

Both materials can be die cut and embossed. Embossed keys give tactile feedback on membrane switch assemblies without a separate component.

Applications

Where our overlays end up

Appliance control panels
Smart card machine overlays
OEM machine overlays
Membrane switch faces and keypads
Instrument and equipment front panels

How to order

Specifying an overlay

Send us the panel drawing with cutout locations, switch travel, embossing requirements and the adhesive specification. We will proof it, produce a physical prototype for fit verification, and manufacture the run.

On the drawing

Cutout locations · switch travel · embossing requirements · adhesive specification · overall panel dimensions

Questions

Answered directly

Send the panel drawing.

Cutout locations, switch travel, embossing and the adhesive specification. We proof it, prototype it for fit verification, and manufacture the run.

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