What are the Differences Between Screen Printing, Digital Printing & Pad Printing?​

What are the Differences Between Screen Printing, Digital Printing & Pad Printing?​

Screen Printing:

Membrane switches have always utilized screen printing to print circuits and graphic overlays. 

Screen printing is a process that uses a woven mesh stencil to transfer ink to the material underneath or substrate. The stencil contains the actual design or artwork. The screen sits atop the product that will receive the image and a squeegee is moved across the screen to fill the open mesh apertures with the ink to create the design on the substrate.

The process was known as silkscreening because silk was originally used as the material. Nowadays, synthetic materials are used in the screen printing process typically polyester, nylon, or stainless steel materials. 

 

Digital Printing:

Digital printing is the process of sending information from a device, typically a computer, to the printer using digital files created by graphics software. The information is reduced to binary code for storage and reproduction. 

Digital printing is ideal for membrane switch designs that are more complex than the traditional artworks such as 3D graphics, textures, fading, half-tones and other effects that cannot be screen printed.

Pad Printing:

Pad printing is a process that transfers a 2D image onto a 3D object. Pad printing is typically used to print images on to more difficult products or surfaces. It involves three main components: an etched plate, a silicone pad to transfer the image, and the substrate. An image is etched into the flat printing plate which is then filled with ink. The silicone pad has a very smooth surface with chemical resistances which is then used to carry the ink from the plate and transfer it onto the object. The silicone material is ideal because it does not absorb the ink and can adapt to irregular shaped surfaces.

CSI Develops Heavy Duty Military Keypad

CSI Develops Heavy Duty Sealed Military Keypad

Product: Heavy Duty Military Keypad

Case: Customer approached CSI requiring an environmentally sealed keypad solution that would not only be able to withstand constant outdoor usage, but more importantly withstand exposure to mustard & sarin gas. 

CSI Final Solution:

  • Liquid-Injection Molded Santoprene (mustard and sarin gas resistant) with debossed graphics and LED indicators
  • 100% environmentally sealed keypad that passes all of the customer’s requirements including mustard and sarin gas resistance.
  • Metal dome switches with LED indicators with additional customer electronics/components integrated into the circuit
  • Copper flex circuit for additional environmental durability
  • Stainless steel backer for rigidity

Designing a Turnkey HMI Assembly

Developing a Full Turnkey HMI Assembly

Designing a full turnkey human machine interface assembly may seem daunting. But CSI Keyboards has over 35 years of experience specializing in the integration of the below technologies into complex user interface turnkey keypad assemblies which has made us the one stop shop for all HMI turnkey interface solutions and front panel input interface assemblies and modules that incorporate electronic components. 

Our broad and diverse product line and engineering expertise allows us to design and manufacture fully integrated interface solutions at a lower cost and better flexibility for our customers. Customers all over the world rely on CSI Keyboards to design, manufacture, and assemble the whole turnkey user interface.

Advantages of an HMI Assembly

By providing the entire value-added assembly, CSI not only minimizes the amount of moving parts for our customers but also overall time and cost. It also allows our customers the ability to place one single purchase order under one single part number for the entire interface. Our longstanding supplier relationships and over 35 years of manufacturing and assembly expertise provides increased control and lower costs for your company.

Medical Keypad Interface Assembly
 
The Medical Diagnostics interface was created for rapid and real-time influenza 
detection. Both its mechanical and electrical design and assembly are tested to
meet medical industry standards.
 
Characteristics:
 
  • Graphic overlay faceplate
  • G10 backer for rigidity
  • Silicone rubber keys with dome switches
  • Display with capacitive touch screen
  • Copper flex circuit assembly loaded with electronics
  • Metal backer for mounting
  • Flex tails exit rear of assembly for connection

CSI Keyboards Update on COVID-19

CSI Keyboards Update on COVID-19

A Letter to Our Valued CSI Customers & Partners,

The State of Massachusetts has issued an emergency order requiring all businesses and organizations that do not provide “COVID-19 Essential Services” to close their physical workplaces and facilities to workers, customers and the public.  We want to ensure you that CSI Keyboards realizes the critical role your products play in the global marketplace and we remain committed to meeting all of your requirements. 

CSI Keyboards will continue our operations as we are considered an essential and critical manufacturer, providing essential products to customers in vital industries: medical, law enforcement, emergency medical services, oil and gas, fire services, transportation services, and national defense services. This, of course, is subject to our Management’s active and ongoing monitoring and contingency planning around any further relevant COVID-19 developments in accordance with applicable federal, state and local health guidelines. 

We are in daily contact with our major suppliers and do not currently foresee any issues meeting your requirements.  We are also aware that many companies are reviewing their inventories and we are prepared to support your increased needs to the best of our ability.  Please let us know if you have any other needs or services with which you think we can assist.  With the everchanging constraints due to COVID-19, we remain flexible in our approach to service your company and manufacture your products.  

CSI Employees continue to practice proper precautions which include (but are not limited to):

  • Social distancing (staying at least 6 feet apart from other individuals).
  • Wearing masks and gloves when necessary.
  • Washing hands frequently and thoroughly throughout the day.
  • Increased hand sanitizing stations throughout the building.
  • Told to stay at home if exhibiting any influenza-like symptoms such as fever, cough or shortness of breath.
  • Temperature of all employees taken at the beginning of each work shift.
  • Notify Management immediately if an employee believes they been exposed to the virus either inside or outside the premises.
  • Absolutely no visitors are allowed on the premises unless they have obtained prior authorization from Management.
  • The building will continue to be disinfected at the end of each day.

CSI values the health, safety and well-being of you and yours.  Please be as safe, vigilant, and proactive as possible. 

As always, please do not hesitate to reach out to us if you have any questions or concerns.

CSI Develops a Full Turnkey Medical Keypad Interface

CSI Develops a Full Turnkey Medical Keypad Interface

 

A customer recently approached CSI requesting a full turnkey medical interface design. Their product required an integrated display, light bar for indicating status of the product (3 colors), IR sensor, a buzzer and four keys. The product is a medical device, so it was also critical that the keypad was environmentally sealed and chemically resistant. 

Medical Keypad Interface Assembly
 
Characteristics:
 
  • Graphic Overlay 
    • Window for Display
    • Window for Light Bar
    • Red Transparent Window for IR Sensor
  • Printed Circuit Board Assembly:
    • TFT Display adhered to rear of PCB
    • IR Sensor mounted to rear of PCB
    • Buzzer mounted to rear of PCB
    • RGB LEDs
    • Light Guide Film 
    • Dome Switches

Backlit Status Light Bar:

By utilizing side-firing LEDs and Light Guide Film (LGF), CSI Keyboards was able to design and develop a membrane switch with an LED light bar. The CSI Engineers used RGB LEDs, ensuring that they were mounted/located in areas on the PCB that would ensure optimal backlighting. The next step was designing the Light Guide Film ensuring the light guide prisms were designed for optimal backlighting and eliminating any chance for hot spots. 

Blue Backlit Light Bar

Blue Backlit Light Bar

Yellow Backlit Light Bar

Yellow Backlit Light Bar

Red Backlit Light Bar

Red Backlit Light Bar

What are UV Resistant Coated Membrane Keypads?

What are UV Resistant Coated Membrane Keypads​

Many of the user interface products designed and manufactured by CSI will eventually live in extremely harsh environments. Some being exposed to UV exposure from the sun for days, months or even years at a time. Luckily, there are methods to protect the keypad from the effects of the sun. One of these methods is using a UV Resistant Coating. 

A UV resistant coating is typically applied to the keys. The coating is glossy in appearance and looks very similar to epoxy coatings that were once used on membrane switches. The major difference between the UV resistant coating and the epoxy coating however, is that the epoxy was not durable. Over time, the epoxy not only became embrittled but it tended to discolor and yellow. 

The UV resistant coating is designed with special barrier resins and compounds that are activated with ultraviolet light. Once activated, they prevent any damage from occurring to the coating or the base material of the keypad.

The UV resistant material’s  “glossy-like” look also enhances the appearance of keypads. The glossy and clean look of the material really makes the product snap and stand out. Between the UV resistant benefits and the enhanced aesthetics, using the UV coating is really a no-brainer when designing a keypad that is going to be used outdoors. 

What Industries Does CSI Serve?

Industries Served

  • Medical : 25%
  • Military : 20%
  • Industrial : 15%
  • Aerospace : 10%
  • Marine Controls : 10%
  • Food Equipment : 10%
  • Agricultural Controls : ≤5%
  • Other : ≤5%

The CSI Advantage

Why CSI?

  • Speed & Efficiency:
    • Concept to Design: ≤ 2 weeks

    • Design to Part: 4-5 weeks

  • Engineering Team: solely focused on keypad and user interface designs

  • Experience: 35+ years, 2500+ custom HMI products, 150+ new designs per year

  • Local Support: Sales, Product Management, Engineering, Quality, Manufacturing

  • Local On-Site Manufacturing, Assembly, Quality, Shipping Teams: ensures parts are built, tested, and shipped to conform to the highest standards

  • Overseas Manufacturing: utilized for larger production volumes and to ensure we can offer the most competitive pricing to our customers

CSI Develops Heavy Duty Sealed Keypad

CSI Develops Heavy Duty Sealed Keypad

Product: Mounted on the outside of an auxiliary vehicle exposed to: water, dust, dirt, ice, rock bombardment, etc.

Case: Customer approached CSI with a keypad that was failing out in the field.

Product Issues:

  • Keypad failing out in the field due to moisture ingress
  • Domes collapsing
  • Graphic overlay fading from UV exposure
  • Lack of tactile response when pressing keys
  • Keypad peeling off of surface
 

CSI Final Solution:

  • 100% Environmentally Sealed Keypad (as a standalone part)
  • Durable and Ruggedized Rubber Keypad Design
  • UV Resistant Keys
  • Improved the Design & Tactility of Keys
  • Upgrade Rear Adhesive for Stronger Adhesion to Surface

The CSI Process

The CSI Process

Concept: The process typically starts with a customer concept which can range from something as simple as a description or a sketch with a list of requirements right up to full keypad drawings.

Design: Once we have enough information on the design, we work up a quote and proposal for the project.  CSI then works on a drawing package which typically takes about 2 weeks depending on complexity of design.  During those two weeks, we are interfacing back and forth with customer. 

Prototype: Once customer signs-off on the design, we built prototype parts which takes about 4-5 weeks.  Because it’s a custom product, there are usually some minor tweaks that take place during the prototype stage such as tactile feel of keys, colors, etc. 

Production: After prototypes are approved, we enter into production. 

Logistics: Work closely with our customer’s procurement team to ensure the customer receives the product when and where they need it. 

Sustainability: After the part has entered into production, CSI sustains and supports the user interface throughout the life of the product.  CSI is still supporting products that were originally designed 37 years.  Some products having gone through some design improvements, while others being built exactly as they were in 1983.