Intro: Silicone Keypads’ Secondary Processes
Secondary, Post-Processing or Finishing Options can all be used to enhance and protect injection-molded plastic parts. Post processing can add functionality or simply provide a uniform appearance. There are a variety of secondary operations that customers can choose from to customize their product. The experts at ICOMold by Fathom have decades of combined experience in the injection-molding field and can lead customers through the process from design, to molding, to finishing operations. Injection molding secondary processes include painting, welding, post-mold machining, assembly, and packaging.
1.Embossed/Engraved Key-Tops
The most economical and durable key top legends are achieved through the embossing or engraving of the silicone directly on the key-top. This method, besides being cost-effective, ensures that the markings remain resistant to wear and allows for features like backlighting using clear silicone. Additional design options include the use of insert molded or flow molded keys to introduce varied colors.
However, it's important to note that embossed/engraved keys are more susceptible to trapping dirt in their corners or recesses. Furthermore, as the legend is an integral part of the mold, any adjustments or modifications would necessitate costly tool modifications. The tooling process, given its requirement for intricate structures, imposes design limitations on the size, depth, and line thickness of embossed/engraved legends, as indicated by the dimensions on the left. Notably, embossed legends are more conducive to the tooling process compared to engraved ones.
2. Silkscreens
Our positive and reverse graphics are achieved through screen printing using our proprietary silicone inks, ensuring a durable bond with silicone rubber keypads and components during curing. These long-lasting graphics endure the lifetime of your keypad under standard industry conditions.
Visually appealing graphics significantly impact user perceptions and product aesthetics. A well-designed keypad not only enhances appearance but also enhances functionality. We often provide recommendations to enhance the design of silicone rubber keypads and their graphics.
Additionally, we've enhanced the silkscreening process, allowing printing on rubber keytops and silicone keypads. Paint serves as the medium to imprint legends onto the key-top surface through a silkscreen equipped with corresponding patterned holes, ensuring precise and consistent application of the legend.
While multiple colors can be blended and printed, each color requires a separate silkscreen, potentially increasing the overall cost with more colors used.
Silkscreen printing, effective when applied flat onto the keytop surface, may not suit convex or concave shapes. Please consider the indicated maximum key top radius. For backlighting, positive or negative silkscreen printing on clear or milky-white silicone provides a cost-effective alternative to laser etching.
3. Color Matching
We utilize the globally standardized color system, namely the Pantone Matching System (PMS). This system allows us to match the color of the silicone itself or any graphic artwork applied to it.
Silkeypad can produce both opaque and translucent silicone colors. The amount of pigment injected into the silicone rubber directly affects the transparency of the final product. We employ advanced instruments to test surface smoothness, transparency, and color of opaque, translucent, and transparent color samples. These highly precise machines enable our technicians to effectively analyze, develop, and control colors in a comprehensive and simplified process.
The color of silicone rubber keyboards is controlled by the quantity and type of pigments used during the molding process. While we use the Pantone system to match silicone colors, we can also match parts with plastic samples or color chips. Due to the unique nature of silicone, keyboards may exhibit color differences under specific lighting conditions, known as metamerism. In such cases, slight adjustments can be made to the pigment formula (e.g., making the color slightly deeper or bluer). Once approved, the pigment formula is locked to ensure color consistency throughout the production and lifespan of the rubber keyboard products.
We are capable of precisely matching pigments for our molded parts and our high-quality silicone-based inks. Silicone-based inks create a permanent bond when applied to silicone products. The mixing and measuring of silicone inks are kept within a fraction of a gram to ensure accuracy and repeatability.
Our high-quality pigments, precise hardware, advanced software, and experienced laboratory technicians aid us in on-site color matching and manufacturing. This significantly enhances the consistency and repeatability of our products while also expediting color matching delivery times
4. Spray Paint & Laser Etch
Another method of adding legends to keytops is through a two-step process: 1) spraying the keytops with paint, and 2) using a laser to "burn off" the paint to add the legends. This is an extremely precise method for creating legends and is highly suitable for backlighting.
The fundamental process for the one-layer spray paint laser & etch includes these steps:
The silicone keypad is initially molded using light-colored silicone.
Next, the entire top surface of the keypad is sprayed with a dark-colored paint.
Finally, the legends are formed by using a laser to remove the dark spray paint, revealing the light-colored silicone underneath.
If the legends require constant illumination, clear silicone can be utilized. However, without backlighting, the visibility of the legends might be challenging.
Regarding laser etching, there is a positional tolerance of +/- 0.1mm, and it's crucial for legends to maintain a distance of more than 0.2mm from any edge. For optimal visibility, the minimum light thickness for legends should be 0.25mm, and there should be a 0.2mm spacing between legends.
5. Coatings
To safeguard against wear and tear over time, both silkscreen printing and spray paint layers often require a protective coating. These coatings serve to shield the legends by providing a clear, seamless layer over the paint. Silkeypadtech offers a range of coatings tailored for different industries, with a preference for matt finish coatings in most applications.
Injection Molding Post Processing Options
- Painting: Painting is one of the cheapest ways to enhance the look of your product. There are various painting methods available including spray painting and powder coating. The type of painting process utilized will be determined by the chemical characteristics of the plastic and its eventual end use.
- Ultrasonic Welding: Silkeypad’s ultrasonic welding process uses high frequency mechanical sound waves to create molecular heat between thermoplastic materials. This will cause the plastic to melt and form a molecular bond between the parts.
- Hot Plate Welding: The hot plate welder uses a heated plate to melt the joining surfaces of the two halves of a thermoplastic part. Hot plate welding allows precise control of the melt temperature, excellent weld strength, and the ability to weld large, complex parts. Heat Pressing: Metal inserts are placed into the plastic parts. This secondary process is done by using heat and pushing the inserts into the parts.
- Heat Staking: This process joins two parts by inserting the stud of one part into a hole in the other part. The stud is then deformed with heat to mechanically lock the parts together.
- Post-Molding Machining: Additional Computer Numerical Control (CNC) machining can be done after the plastic injection molding process is completed. This machining can be used to remove flash (excess plastic), change the shape or texture of the part, or prepare the part for further post processing.
- Pad Printing & Screen Printing: Pad and screen printing are used to place colored graphics on parts. This can be done for branding, labeling, or part number identification. Screen printing is ideal for adding graphics that require multiple colors. However, there are some limitations to the screen-printing process. Screen printing requires a relatively flat surface for printing. Pad printing is a versatile finishing option. Pad printing can be used almost anywhere on the part.
- Assembly: Silkeypad by Fathom can assemble the parts if needed. Simply supply all needed materials and Silkeypad will take care of the rest. Parts will arrive fully assembled and ready for use.
- Packaging: Silkeypad can produce, assemble, and package your product. After production and assembly, the parts can be packaged into clamshell/blister packs, boxes, insert header cards, etc. The product will be packaged and ready to sell or ship out upon delivery.
Enhancing Appearance: Painting
Enhance your product's visual appeal cost-effectively through painting. Multiple methods such as spray painting and powder coating are available. The chosen painting technique depends on the plastic's chemical properties and intended final application.
Precision Bonding: Ultrasonic Welding
Leveraging high-frequency mechanical sound waves, Silkeypad's ultrasonic welding generates molecular heat between thermoplastic materials. This induces plastic melting and establishes a strong molecular bond between parts.
Robust Joining: Hot Plate Welding
Utilizing a heated platen, the hot plate welder melts surfaces of thermoplastic parts. It ensures meticulous control over melt temperature, impeccable weld strength, and the capacity to weld intricate, large components. Explore our hot plate welding video for in-depth understanding.
Functional Integration: Heat Pressing
Enrich plastic parts with metal inserts through heat-infused integration. Metal inserts are introduced via heat and pressure, seamlessly incorporating functional elements within the parts.
Mechanical Locking: Heat Staking
Merge components through heat staking, wherein a stud from one part is inserted into another part's hole. Application of heat deforms the stud, creating a secure mechanical lock between parts.
Refining Precision: Post-Molding Machining
Refine plastic injection molded parts via Computer Numerical Control (CNC) machining post-molding. This process eliminates excess plastic (flash), modifies part shape or texture, and prepares parts for subsequent post-processing stages.
Custom Graphics and Branding: Pad Printing & Screen Printing
Add colored graphics to parts for branding, labeling, or identification using pad and screen printing. Screen printing is ideal for multi-color graphics, while pad printing offers versatile placement possibilities. Note that screen printing requires a relatively flat surface.
Seamless Assembly
Silkeypad facilitates seamless assembly if required. Supply the necessary materials, and we handle the assembly process. Delivered parts arrive fully assembled and ready for immediate use.
Efficient Packaging
Silkeypad streamlines your product journey by providing production, assembly, and packaging services. Following production and assembly, parts can be meticulously packaged in clamshell/blister packs, boxes, insert header cards, and more. The packaged product is ready for sale or shipping upon delivery.
Post molding process for silicone parts
The post-molding process plays a pivotal role in refining and enhancing the performance, aesthetics, and functionality of silicone parts. These essential secondary operations ensure that the final silicone components meet the highest standards and specifications. At Silkeypad, we offer a comprehensive range of post-molding processes tailored to optimize the quality and value of your silicone parts.
Surface Finishing: Painting and Coating
Achieve a flawless and captivating appearance for your silicone parts through precision painting and coating techniques. Our experts meticulously apply specialized paints and coatings to enhance visual appeal, provide protective layers, and ensure resistance to environmental factors.
Functional Integration: Insert Molding
Elevate the functionality of your silicone parts through insert molding, where metal or other materials are integrated within the silicone structure. This process enhances versatility, allowing for the incorporation of features like threaded inserts or metal reinforcements.
Customized Graphics: Printing and Marking
Enhance brand visibility and product identification with precise pad printing and marking techniques. Whether for branding, labeling, or essential information, our printing solutions offer clear and durable graphics that withstand environmental challenges.
Assembly and Packaging
Ensure a streamlined production cycle by leveraging our assembly and packaging expertise. Our team can seamlessly assemble silicone components and package them to your specifications, ensuring they are ready for immediate use or distribution upon delivery.
Quality Inspection and Compliance
Every silicone part undergoes meticulous quality inspection to ensure it meets the highest industry standards. Our rigorous quality control processes guarantee that each component meets its intended specifications and complies with relevant regulations.
Why Choose Silkeypad for Post Molding Processes of Plastic and LSR Parts？
When you want to achieve the highest-quality plastic parts, it’s important to understand the properties of common resin types, the available assembly methods and finishes, as well as why opting for plastic instead of metal parts is beneficial. At Wunder Mold, we’ll provide you with the information you need to achieve optimum results and suggest solutions that match your needs and specific requirements.
With over 24 years of experience in the industry, we keep striving to advance the scope, quality, and cost-efficiency of our processes. With the highest-quality materials and workmanship, and detail-oriented methods, you can rest easy knowing that the benefits you can reap are many.
Expertise in Materials: Silkeypad boasts extensive knowledge of both plastic and LSR (Liquid Silicone Rubber) materials, enabling us to recommend and apply the most suitable post-molding processes for optimal results.
Precision and Consistency: Our advanced post-molding techniques ensure precise and consistent outcomes, enhancing the functionality, appearance, and performance of your plastic and LSR parts.
Customized Solutions: We understand the unique demands of different industries and applications. Our tailored post-molding processes address your specific needs, delivering solutions that align perfectly with your requirements.
State-of-the-Art Facilities: Equipped with modern facilities and cutting-edge technology, Silkeypad is capable of executing a wide range of post-molding treatments with efficiency and excellence.
Quality Assurance: Our commitment to quality is unwavering. We implement rigorous quality control measures at every stage of the post-molding process to ensure your plastic and LSR parts meet the highest standards.
Comprehensive Services: From surface treatments and coloring to assembly and packaging, Silkeypad offers a comprehensive suite of post-molding services, streamlining the entire process and saving you time and effort.
Finish your silicone keypad jobs with Silkeypad
Flexibility in design: The flexibility in design is a significant advantage of silicone rubber keypads, allowing customization according to specific product requirements. This encompasses various surface treatments, 3D shapes, and even backlighting options, enabling tailored designs without compromising quality or durability.
Safety in operation: Furthermore, the ergonomic design of silicone rubber keypads enhances the user experience by maximizing tactile sensation. This feature aids users in effortlessly locating control buttons, even while wearing gloves or when visual contact is not possible, ensuring safe and intuitive product operation. Ensuring safety and intuitive operation are crucial for overall user experience and product satisfaction.
Long life cycle and durability: additionally, silicone rubber keypads possess a long lifespan and durability, making them suitable for various environments and capable of withstanding harsh conditions and diverse environmental influences. Surface treatments further reinforce their resilience against dust, dirt, and other contaminants, thus extending their operational lifespan.
Regarding collaboration with Silkeypad, this likely involves their provision of services or products aimed at enhancing or completing silicone rubber keypad projects. This collaboration may offer additional technical support, design suggestions, or specialized processing techniques to improve the quality or completion of silicone rubber keypad projects.
In conclusion, silicone rubber keypads are preferred across various applications due to their customizability, operational safety, and durability. Collaborating with companies like Silkeypad may further enhance the quality or completion of silicone rubber keypad projects.