Graphic Overlays Printing Basics - at a Glance

Information | Instant Quote| Samples

Overall Size and Shape | Internal Cutouts | Transparent Windows | Adhesive Free Areas

Overall Size and Shape [top]

Our capabilities include cutting graphic overlays that are up to approximately 11.9" in the shortest dimension. Because we cut our graphic overlays digitally, our accuracy is much tighter than with conventional dies. We cut within 1/64". The actual shape of your control panel overlays can include as many edge line changes as required to fit your application.

Size and shape are digitally cut from a Lexan® sheet which reduces waste and eliminates the need for costly dies.

Internal Cutouts [top]

Internal cuts used to fit cable jacks, buttons or switches can be done in any configuration, in any number of sizes and shapes, and in any location on your graphic overlays. Odd cuts that require tight tolerances are much easier to control with our digital Lexan® cutting techniques. There is no limit to the number of internal cut outs that we can do. Contact us!

Transparent Windows [top]

We offer 7 transparent inks that are well-proven to allow better than acceptable levels of show through on Lexan® graphic overlays. The size and shape of your transparent windows is unlimited. Similarly, you can add multiple transparent areas or windows as needed. This design feature coupled with our digital printing capability enables you to design graphic overlays for almost any application.

Adhesive Free Area [top]

An adhesive free area is created by masking the area not to be covered with adhesive. While some limitations can come into play when creating graphic overlays with adhesive free areas, we generally can "mask" the adhesive in multiple locations and in almost any size or shape. If your graphic overlays will include adhesive free areas, be sure to contact customer service with questions.

Get an instant quote for your graphic overlays

Graphic Overlays - Materials

Our printing of graphic overlays is done digitally on these materials:

• 10 mil Velvet Lexan® (UL) adhesive free
• 7 mil Velvet LexSaver™ Poly (UL)
• 7 mil Velvet LexSaver™ Vinyl (UL)

For more detailed information on each of these graphic overlay materials, please read below.

Lexan® 10 mil is the most common material used for electronic control panels and graphic overlays. 10 mil clear Lexan® is a poly carbonate finished with a velvet top surface texture. A 2 mil or 5 mil adhesive, either 3M 467MP or 3M 468MP, is laminated over the printed back surface, and the graphic overlay and its internal cutouts are then cut away from the Lexan® material. The sub-surface printing is now protected by 10 mils of Lexan®. The velvet finish surface masks minor surface scratches keeping the graphic overlays looking like new for years. Transparent colored inks and clear (non printed) areas can be designated for display panels, or LED's. Adhesive free areas ("patterned adhesive") can be included as required under designated switches or display window areas.

The LexSaver™ materials include a substrate material of either vinyl or poly that has been treated with a pre applied pressure sensitive adhesive on a release liner. The vinyl or poly is then printed, over laminated with a 5 mil velvet surface Lexan® and cut as required. The outer shape of the control panel and the interior cuts are then cut through only to the release liner. The remaining substrate is stripped away allowing the graphic overlays to remain in place on the roll of the release liner.

The LexSaver™ process is typically more cost-effective than subsurface printing of 10 mil Lexan®. LexSaver™ graphic overlays tend to be amore flexible and less likely to exhibit minor cracking when the graphic overlay is used over a membrane switch or over micro switches.