When designing a custom keyboard, one of the most important considerations is the keycaps, as they directly impact both the functionality and aesthetic appeal of the keyboard. There are several different methods for creating plastic keycaps, each with its own unique characteristics and benefits. From silkscreen printing to double-shot molding, these techniques allow designers and manufacturers to create keycaps with a range of options for durability, appearance, and usability.

In this blog post, we will take a deep dive into the different plastic keycap options available for custom keyboards and explore the unique advantages of each method. Whether you’re looking to customize the feel, look, or longevity of your keyboard, understanding these keycap processes will help you make an informed decision.

1. Silkscreen Printing for Plastic Keycaps

Silkscreen printing is one of the most widely used processes for applying legends (the characters on the keycaps) to plastic keycaps. This method involves applying ink through a mesh screen onto the surface of the keycap, and it’s particularly popular due to its cost-effectiveness.

While silkscreen printing offers a low production cost, it does have some limitations. The lifespan of the characters printed using this method is generally shorter compared to other processes. Over time, the printed characters may wear off, especially with frequent use. However, a UV coating can be applied over the characters to increase their durability and help prevent them from wearing down. This is a common solution for making silkscreen-printed keycaps more resistant to abrasion and fading.

Silkscreen printing is ideal for situations where cost is a significant factor and the keycaps do not need to endure excessive wear and tear. It’s a great option for low to mid-range custom keyboards where you may want to keep production costs low without sacrificing too much in terms of visual appeal.

2. Laser Etching for Plastic Keycaps

Laser etching is another popular method used for applying legends to keycaps. This process involves using a laser to etch the characters directly onto the keycap’s surface. Laser etching is commonly used in both silicone rubber keyboards and plastic keycaps, and it offers more durability than silkscreen printing.

There are two primary types of laser etching for keycaps:

– Direct Laser Engraving: This method involves engraving the characters directly onto the surface of the keycap without any additional processes. The characters are typically white, as the laser removes the color from the keycap material, leaving a contrasting white etching.

– Laser Etching with Color Application: In some cases, a different process is used where the keycap is first sprayed with a colored coating. Afterward, a laser is used to etch out the characters, creating a design with multiple colors. This method allows for more flexibility in design and can result in more visually appealing keycaps with a variety of color options.

Laser etching is a durable solution that can result in long-lasting keycap legends. The etching process ensures that the characters will not fade over time, making it a good option for high-use environments or where long-term durability is important.

3. Double-Shot Molding (Dual Injection Molding)

Double-shot molding, also known as dual injection molding, is one of the most advanced techniques used to produce keycaps. This method involves injecting two different types of plastic into a mold to form a single keycap. The two pieces of plastic are molded together, creating a seamless keycap with transparent legends that allow for backlighting.

Double-shot keycaps are highly durable, and one of their main advantages is that the legends will never wear off. This is because the legends are molded into the keycap rather than being applied to the surface. Double-shot molding ensures that the keycap legends are permanently embedded in the material, making them highly resistant to wear and tear.

This process is often used for high-end mechanical keyboards, especially those that feature RGB backlighting. The transparent legends allow the backlighting to shine through, creating a visually stunning effect. Double-shot keycaps are typically available in both PBT (polybutylene terephthalate) and ABS (acrylonitrile butadiene styrene) plastics, with PBT being more durable and resistant to wear, and ABS offering a smoother feel.

Although double-shot molding is more expensive than other keycap processes, it’s the preferred choice for users who want the highest quality keycaps with lasting durability and beautiful backlighting effects.

4. Laser Etched Legends on the Backside of Keycaps

An alternative approach to laser etching is to engrave the legends on the backside of the keycap rather than the front. This technique offers enhanced durability, as the characters are less likely to be exposed to wear and tear. Since the legends are on the inside, the outer surface of the keycap remains pristine, protecting the markings from physical contact.

This method is especially useful for keycaps that will be exposed to heavy use, as the laser-etched legends will remain intact for much longer compared to traditional laser engraving. The backside etching process ensures that the characters will not fade over time, providing a long-lasting solution for users who require durable keycaps.

5. Hollowing Out Silkscreen Printing (Backlit Option)

For keycaps that are designed for backlighting, a process known as hollowing out silkscreen printing can be used. This method involves creating cut-outs or hollow sections in the keycap where the legends are placed, allowing light to pass through and illuminate the characters.

This technique is often used for ABS plastic keycaps, as ABS offers better translucency than other materials. Hollowing out silkscreen printing is commonly used for backlit keycaps, especially for gaming and professional keyboards, where illuminated legends can enhance both the appearance and functionality of the device.

The backlighting effect created through this method is visually appealing, making it a popular choice for custom keyboards, especially in low-light environments.

6. Plastic Keycap Protective Coating

To further enhance the durability of plastic keycaps, manufacturers often apply protective coatings to the surface. Two common coatings used for this purpose are:

– Ultraviolet (UV) Curing Coating: UV curing coatings are applied to keycaps to improve their resistance to wear, fading, and dirt accumulation. This coating is hardened using UV light, creating a strong and long-lasting layer of protection for the keycap surface. UV coatings are ideal for keycaps that will be exposed to heavy use, as they provide additional protection against scratches and stains.

– Polyurethane (PU) Coating: PU coatings are applied to keycaps to provide a smooth, glossy finish and protect the surface from damage. This coating is particularly effective at preventing keycap legends from wearing off, making it a good choice for keycaps that will be subjected to constant use.

Both UV and PU coatings can significantly extend the lifespan of plastic keycaps, ensuring that the legends remain intact and the keycaps continue to perform well over time.

Why Choose Rockeypad for Your Custom Keycaps?

At Rockeypad, we understand the importance of high-quality keycaps for your custom keyboard. Whether you’re looking for durability, aesthetic appeal, or advanced backlighting options, we offer a wide range of keycap solutions to meet your needs. Our team is dedicated to providing you with the best possible keycap materials, coatings, and customization options for your project.

With over two decades of experience in the industry, Rockeypad is the trusted partner for creating keycaps that are not only functional but also visually stunning. We pride ourselves on delivering exceptional customer service and high-quality products that meet the unique needs of our clients.

If you’re looking to create a custom keyboard that stands out, contact us today to learn more about our keycap options. Let us help you bring your vision to life with precision-engineered, durable, and aesthetically pleasing keycaps that will enhance the usability and appearance of your keyboard.