GSM Graphic Arts were approached by a company that makes automatic door controllers used in farming and agriculture. These controllers are used around the world in many different climate conditions, from Australia’s sunlight to Canada’s freezing winters.
The controllers required an overlay to fit over an existing moulded case; this case had 3 push button switches and an LED display unit, but it was specified that the switches would be used infrequently once the unit was set up.
Because our graphic overlay work is so extensive, from embossing and cut-outs for switches to transparent LED windows and anti-glare LCD windows, we knew we could provide our client with exactly what they were asking for.
The Challenge:
As the controllers would be positioned outside, the customer wanted an overlay that would seal the unit by incorporating a clear display window and embossed buttons. However, the concern was the height of the moulded buttons in the case, which were measured at 1mm high, meaning we had to look at different embossing options to see how we could achieve this height.
Therefore, we looked at different embossing options to see how we could achieve this height or embossing, but it seemed that this would incur CNC-machined tooling at a cost in the region of £1500.
Upon further investigation, it was felt that this tooling wouldn’t necessarily guarantee the emboss height required. Additionally, there were concerns regarding the durability of the embossing at that height, so we decided to take a step back.
After discussing the matter further with the customer, we agreed to sample a standard emboss tool that gave a switch emboss height of 0.4mm at a cost of £200; we’d then also produce spacer samples of different thicknesses, which would be used behind the overlay to bring the embossed switch to the correct height.
The Solution:
The samples were produced and sent to the customer for evaluation. It was decided that the 0.375mm spacer assembled behind the overlay achieved the switch action required when pressed whilst still clearing the switch.
The overlay and spacer stayed within the 0.5mm recess depth, ensuring that the edges of the assembly remained protected.
We have now produced 18,000 of the overlays and spacers with the customer’s confidence that the control panel overlay meets the required specifications.
Does your project need custom graphic overlays, fascias or labels? Then contact our sales team on 01845 522184 or click here to request a quotation and start your journey to aquire the highest quality components from the leading label manufacturers in the UK today.
