When it comes to manufacturing overlay graphics, there are more factors to consider than you might think. They may get overlooked from time to time, but they have a significant purpose for serving customers that should not be taken for granted.
You most likely encounter these graphic overlays on a regular basis, but have you ever stopped to consider what goes into their creation? Probably not, so we are here to tell you everything you need to know about the manufacturing of overlay graphics.
First, we should discuss the purpose of graphic overlays and how they are used. Let’s dive right in.
What Are Overlay Graphics Used For?
In a world of advanced technology, we have developed a need for a way to connect a machine to its user. The complexity of our technology must be simplified in a way that people can understand and actually put it to use, and that is where graphic overlays come into play.
With overlay graphics, the functionality of a machine is effectively outlined to make it easily accessible and navigable by its users. Picture a TV remote with no numbers or dials on it. It would be pretty useless to the average user, right?
That’s why graphic overlays, also known as nameplates, are important for establishing the functionality of a machine. Without them, it would be almost impossible to decipher the purpose of electronics such as keypads, display boards, switches, speakers, and much more.
Usually, overlay graphics are composed of thin layers of plastic or polymer material that are placed over an electronic device. These display the printed material, text, or other graphics that indicate how to use the device or machine.
Custom Graphic Overlay Design Considerations
When companies need specific overlay graphics for their products, there are a few elements they need to consider to achieve the optimal design for the product’s application. So, let’s explore some of the main design elements for choosing the perfect graphic overlay.
Size Specifications
Before delving into the numerous design possibilities, you need to calculate the size, shape, and placement of your overlay graphics. Doing this early on is beneficial because it influences key aspects of the decision-making process.
Also, another element to consider is the thickness of the overlay material because this will affect how the user interacts with the product.
Environmental Durability
It is important to determine the practical use of the product before picking your design. As a part of the manufacturing process, you need to consider the environment that the device will be used in.
Since graphic overlays are used in countless settings, the environmental condition plays a key role in choosing the material and design components. With countless applications in indoor, outdoor, and sterile environments, the durability of the graphic overlay depends on these conditions.
Features and Functionality
Customized graphic overlays can include features that enhance company branding and improve the users’ experience. For example, add-ons like tactile switches, dead-front panels, and LED illumination are all options that augment the user interaction with the device.
The 10 Key Elements of Manufacturing Overlay Graphics
So, now that we’ve established some of the uses and factors to consider with overlay graphics, let’s discuss the important elements of graphic overlay printing.
1. Material
Choosing the right material depends largely on the environmental conditions in which the device will operate, including temperature, moisture, exposure to chemicals, and general wear and tear. Selecting the correct material ensures durability, longevity, and optimal performance for the specific application.
Polycarbonate
- Suitable for both indoor and outdoor use
- Offers excellent optical clarity for clear displays and visual depth effects
- Allows flexible design options for complex shapes and graphics
- Highly impact-resistant, protecting against accidental drops or mechanical stress
- Performs well in extreme temperatures
- Resistant to scratches, corrosion, chemical abrasion, and water, making it ideal for demanding environments
Polyester
- Ideal for harsh indoor and outdoor environments
- Provides strong UV resistance to prevent fading over time
- Electrically resistant, making it safe for electronic applications
- Can withstand extreme temperatures, water exposure, abrasion, and chemicals
- Resistant to tears, ensuring long-lasting durability
- Commonly used in commercial and industrial applications where reliability is critical
Working closely with your manufacturing partner can help you evaluate your operational environment and determine which material best meets the needs of your overlay application. Proper material selection not only improves the lifespan of the overlay but also enhances the overall user experience.
2. Printing
The printing method shapes the look, durability, and cost of your graphic overlay.
Digital Printing
Perfect for high-resolution, full-color designs and short runs. Offers fast setup, unlimited colors, and precise details, ideal for prototypes, limited editions, or overlays with variable information like QR codes.
Screen Printing
Best for long runs and heavy-use environments. Delivers bright, durable colors, fine details, and special effects like metallic inks or tactile finishes, making it ideal for industrial or commercial applications.
3. Custom Fabrication
All of the following considerations will touch on different customizations that occur in the manufacturing stage of graphic overlays. Custom fabrications, especially font style and size, are key components that affect the user interface.
Since the purpose of a graphic overlay is to facilitate effective interactions with the device, using legible fonts and easily comprehensible language is of the utmost importance.
4. Color Management
The colors used in your overlay graphics should be consistent with your company’s branding and support the user experience. Consider using contrasting colors to make the important elements of the overlay stand out. There are two main types of color printing for graphic overlays: process color printing and Pantone color matching.
Process color is more cost-effective and involves a printing process similar to ink cartridges for printers that creates layers of four base colors: cyan, magenta, yellow, and black. Pantone color matching systems (PMS) use exact matching, which is a great option for companies that need precise colors on their overlay graphics.
5. Embossing
Embossing is a design functionality used in graphic overlays that incorporates raised elements to make certain features more prominent and tactile. By adding a physical dimension to the overlay, embossing enhances both the visual appeal and usability of the device, guiding users’ attention to important areas.
There are several types of embossing commonly used:
- Pad Embossing: Creates isolated raised areas for buttons or key features, allowing for precise tactile feedback
- Perimeter (Rim) Embossing: Highlights the edges of a feature or panel, making boundaries clear and visually distinct
- Dome Embossing: Produces a rounded, dome-like effect for buttons or icons, offering an ergonomic and noticeable touch point
- Braille Embossing: Improves accessibility compliance and serves visually impaired users
Embossing is especially valuable in situations where users rely on touch as much as sight, such as control panels or industrial equipment. It not only improves functionality by making key details easier to find but also adds a professional, premium look to your overlay graphics.
This subtle design enhancement can draw attention to details that might otherwise go unnoticed, improving both user experience and operational efficiency.
6. Windows and Cutouts
Including a window or cutout on your overlay can increase user efficiency and allow visual access to important information on the machine. Windows and cutouts can help indicate a click-on or off button, or device status, such as a low battery.
These can come in colored tints and different finishes, like glossy, semi-gloss, anti-glare, dead-front, translucent, or frosted.
7. Adhesive
To ensure your graphic overlay is durable for years to come, you need an adhesive that guarantees lasting and effective use. Some elements of the adhesive to consider are surface energy, bonding material (plastic or metal), and surface conditions (smooth, textured, etc.).
As the final layer of your graphic overlay, it is crucial to incorporate spaces to ensure the adhesive has corresponding spaces for windows, embossed buttons, and cutouts. To allow an easier application of the adhesive, use back-splitting to peel back one side of the liner.
Your overlay graphic manufacturer should provide guidance on which adhesive will be best for your product.
8. Lighting
Both internal and external lighting will have an impact on your overlay graphics. External lighting coincides with the environmental conditions in which the device will be placed. These include exposure to UV light, intense lighting, or dim lighting, which would all affect the display of the overlay graphics.
Internal lighting refers to the light that comes from inside the device. Backlighting can help improve legibility for buttons and add functionality like the window indicators we mentioned in the section above.
9. Finishes
The finish of your graphic overlay will set the stage for the user’s first impression of the device or machine. Surface finishes like protective coatings, metallic finishes, anti-glare, textured, and antimicrobial coatings can be applied for practical and aesthetic purposes.
Finishes also contribute to the durability and appearance of the overlay, so be sure to determine one that suits the purpose of your product.
10. Adhesive
Every graphic overlay should go through thorough quality control before leaving the facility. This includes checking adhesion strength, resistance to environmental factors like heat, moisture, UV, and chemicals, print quality, embossing accuracy, and overall dimensions.
Rigorous testing ensures each overlay performs reliably and meets all industry standards and specifications.
Choose an Experienced Manufacturer For Printing Graphic Overlays
Now that we have covered the most important aspects of your overlay graphics, you can see that there are a lot of considerations that go into your final product. Although the choices can be overwhelming, having an experienced graphic overlay printing professional on your side is helpful.
At Hallmark Nameplate, we specialize in nameplates and graphic overlay printing for numerous industries, such as aerospace, food service, medical fields, automotive industries, telecommunications, and more.
We use advanced systems and technologies to develop custom applications, so your equipment turns out exactly how you want it to be. Fill out a comprehensive, FREE quote to find a solution that will meet your specific needs, and we will be happy to work with you.
