Graphic Overlays

Overlay Materials: Graphic overlays are produced almost exclusively on transparent materials most commonly polycarbonate and polyester but occasionally on transparent textured vinyl, PETG, or acrylic. Consideration for the surface the overlay will be applied to, and environmental conditions is important when selecting the correct overlay material as well as the adhesive to apply behind the overlay printing.

Overlay Printingcan achieved with either digital, screen or lithographic printing processes. Printing is nearly always “2nd surface” in so far as the ink is viewed through the transparent material, and the overlay material provides wear resistance for the printing when the overlay is in use. The appropriate printing technology is dependent on factors such as indoor vs outdoor use, color matching precision requirements, use of gradients, half tone or full color images, production quantity, part size, and number of colors, and turnaround time requirements.

Overlay Die-cutting: Graphic overlays can be either digitally cut (e.g., digital knife plotter, laser, water jet, routed) or with cut with hard tools (e.g., steel rule dies or die sets)

Overlay Embossing:. Overlays can be either full key embossed ("pillow"), or rim embossed around the key perimeter. On occasion customers may request that logos be embossed on graphic overlays, or that selected areas of the overlay be raised to accommodate above surface light emitting diode (LED) illumination.

LCD and LED windows are commonly created in graphic overlays by leaving selected area's un printed.