Rubber Keypad Manufacturing Process
Below are some images from the silcone rubber keypad manufacturing process. Including, making the tool, adding colors, and screen printing. All our rubber keypads go through intensive testing and quality control during each step of the manufacturing process.
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Making the ToolIn-house tool making with state-of-the-art EDM and CNC milling machines. -
Conductive PillsCarbon impregnated silicone pills are the most frequently used contact with silicone rubber keypads. The silicone in the conductive pill allows enables it to securely co-mold with the keypad. -
Placing the Silicone Rubber on the ToolGum stock silicone rubber is placed directly on tool. Heat and pressure will form the silicone into the configuration of the mold tool. -
Stage 2 – Keypad After Molding CyclePressure and heat are maintained until the material has cured. The mold is opened and the keypad sheets are removed for further processing. -
Adding Several ColorsPigmented silicone rubber is hand placed onto the base mat in preparation for molding. The silicone will blend together to form the keypad base while the keys will retain their specific colors. Only the key tops will be seen throught the bezel. -
Removing the Keypad from the ToolAir hoses are used to assist in removing the keypads from the mold tool. The carbon pills were placed in the bottom of the tool prior to adding silicone and molding. As you can see, they are now molded to the keypad. -
SilkscreenMolded silicone keypads are placed in a vacuum fixture for screen printing. Silicone in the inks bond to the keypad during the curing process and flexes during keypad actuation. -
Screen PrintingA stencil is placed over the keypad. The stencil exposes only the key tops that are to receive ink on this screen printing pass. Each screen print color will have a stencil. -
TestingThe silicone rubber keypads are tested to insure they meet our customers' mechanical and dimensional tolerances. The technicain is testing the operating force of a key. -
Quality ControlAfter the molding process and post curing the silicone rubber keypads are removed from the sheet and inspected for quality issues.
