Prototyping trends in keypads and overlays

Paul Bennett, Managing Director of Fascia Graphics, discusses why businesses are demanding rapid digital prototypes.

Successfully launching a product into the market depends on fast, efficient product development coupled with quick and flexible manufacturing processes.

For all sorts of electronics companies speed to market is essential, and this is why rapid digital prototyping of membrane keypads, graphic overlays and labels has evolved.

Fascia Graphics recently conducted research across 50 electronics engineers working in the medical, catering, fire, security and electronics sectors, which found that although only 40% are currently using digital prototypes, 90% are predicting that the digital prototyping industry will continue to grow over the next five years.

Our research also found that whereas taking an idea for a new product through to production can often be the start of a long, laborious and expensive journey to production, many are finding that this need not be the case as digital prototyping can reduce expenditure and operating costs, provide rapid time to market and the ability to maximise the latest technologies.

40% of engineers said the most important benefit of manufacturing a digital prototype is a fast turnaround of product, with 20% stating that it also allows modifications to the product before paying out for a full set of artwork and tools.

There is also the issue that the customer of a membrane keypad or graphic overlay often falls into two groups.

Whether they are a large OEM, a design house or just someone with a great idea, they either know exactly what they want or they really are not sure.

In either case, a digital prototyping solution can be developed for a fraction of the cost without investing into expensive tooling.

One of the key drivers of rapid digital prototyping is the need for prototypes at exhibitions and shows, with our research finding that 40% of electrical engineers citing the most important benefit to using digital prototypes - that it increases the likelihood of more sales at shows/exhibitions - with 60% stating that a professional prototype enhances their businesses chance of a sale at a show/exhibition/during a sales presentation by over 80%.

It is also important to note that 80% of the engineers questioned said that they didn't even start thinking about the production of a prototype less than three months before the show, let alone start the production process.

This further demonstrates the importance of component parts (such as overlays and keypads) being developed quickly and cost effectively.

But it is not just for the reasons of the sales pitch that digital prototypes are being used; businesses are also using them to obtain valuable feedback from the shop floor, marketing, executive teams and customers.

It is also coming to the forefront as a key part of the product development stage as it offers more realistic visualisation; producing something that you can get your hands on.

As digital keypad and overlay prototyping (like all prototyping) helps you review the design prior to going into full manufacturing, the product development process can also be analysed close and hard, leading to higher sales volumes and profits when a more polished product is launched.

Using a digital prototype of a membrane keypad or graphic overlay can also shorten horizons.

For instance, it is easier to predict what will happen tomorrow than what will happen next month.

Therefore, reducing the time between conceiving, producing and selling a product greatly improves the ability to forecast demand or interest.

So, if you are two weeks from an important show or exhibition and your competitor launches a product that is visually identical to the one that you have in development, you still have time to alter the look of the product without a great investment.

We have even had cases where a keypad or overlay is taken through full development for this very point in 48 hours.

With digital overlays and membrane keypads now an integral feature of a professional electronic prototype, here are the top ten reasons why engineers are using them.

1) Low cost prototypes.

2) Fast turnaround.

3) Next to no artwork or tooling costs - a tool will only be required if the part is embossed.

4) Allows businesses to approve the product before paying out for a full set of artwork and tools.

5) A fully operational membrane can be delivered within five working days.

6) Ideal for exhibitions and shows where a low cost product is required to attract potential customers.

7) Front printed and reverse printed materials are available.

8) Serialised labels are available.

9) Integral LEDs can be incorporated into digital membranes.

10) Low volume resin domed badges and vinyl cut letters are available on the digital printer.

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