High Performance Membrane Switches

• Facilities: Milwaukee, WI USA & Huizhou, China
• Capacity: 1 to 1,000,000
• Printing Methods: Screen print, roll-to-roll & digital process (offset)
• Digital Printing: Roland UV printers offer high quality low volume printing option for small volume & rapid prototype production.
• Lighting Features: Integrated LEDs, backlighting, EL lamps, fiber optics
• Design Options: Embossing, dead fronts, tints, tactile response
  
• Outdoor Applications: Gaskets, design review, & material selection for any environment
  
• Circuits: silver, copper flex (FPC), & printed circuit boards (PCB)
• Metal Keypad: durable high quality construction. Custom & stock designs.
• View our product gallery for more membrane switch design ideas.

Membrane Switch Design Guide

Mechanical

• What material type is the switch laminated to? This will determine the adhesive needed.
• Will tactile response be required?
• Is actuation force a factor? The usage affects whether you want a heavy or light force to actuate the key.

Environmental

• Will this product be used indoors or outdoors? Does this product need NEMA 4 construction? NEMA 4 provides a degree of protection against falling dirt, rain, sleet, snow, windblown dust, splashing water, and hose-directed water.
• Is this product exposed to the elements?
• What temperatures and humidity range will this product experience?
• What type of solvents and cleaning solutions will come into contact with the switch?

Electrical

• How many switches will there be?
• What type of pinout will be used (common bus, X-Y matrix, other)?
• What closed loop resistance is acceptable?
• Will Electromagnetic (EMI) or Electrostatic (ESD) shielding be necessary?

Appearance

• Will edges be exposed? It is best to place the membrane switch into a recess that is the same or greater thickness as the membrane switch to avoid accidental interaction.
• Will embossing be required? Embossing improves a user’s ability to locate keys.

Design Stage

• Adobe Illustrator - AI or EPS
• CorelDraw - CDR
• AutoCAD - DWG or DXF
• Portable Document Format - PDF

• Design support team ready to assist
• Color printed proofs (when needed)
• Artwork is approved by customer before any production run is started.

• Rapid prototypes
• Precision laser cut prototypes
• Fast implementation of design changes and updates

Graphic Overlay Design Elements

• Pre-textured material or printed textures
• Sample finishes are available upon request

• Perimeter embossing requires a minimum distance of .030” to the edge of the material.
• Key-to-key distance should be a minimum of .050”

Tactile Feel

Lighting Design Elements

• 0.10” pitch Male, Female, and Solder Tab
• Plating-Tin or Gold

• This connector is designed for installation of ZIF Connectors
• 1mm spacing

• Custom Molded Plastic – injection molded plastic built to your specifications
• Plastic Panel (acrylic, Lexan, polycarbonate, etc…) – flat die cut or laser cut plastic in a variety of thicknesses
• Aluminum – brushed, anodized, sealed, unsealed, dyed
• Cold Roll Steel - plated with chrome, zinc, or other plating
• Stainless Steel - brushed, sanded, and other finishes.

References

A. Die Cutting Tolerances

B. Membrane Switch - Electrical and Mechanical Specifications

Electrical

Mechanical & Environmental

C. Membrane Switch Blueprints

D. Glossary

• Screen Printed Overlays : Print on any thickness of plastic. Screen printed overlays & signage are very durable and can be used indoors or outdoors. Colors are printed one at a time and can be matched to a Pantone color specification (PMS) or to a customer supplied sample.

• Digital Printing: Roland UV printers offer high quality low volume printing option for small volume & rapid prototype production.

• Offset Printing : 4 color process printing for larger quantity thin plastic signage, membrane switches, and graphic overlays.

• Dome Labels : Custom 3D dome labels for high visibility nameplates.

• Roll Stock Labels : High quality roll stock labels for a variety of uses including UL, tamper proof, outdoor, address, and more.

• Pad Printing : Printing on curved and irregular surfaces using a soft rubber pad to transfer the image.

• Laser Cutting Prototypes or Low Volume Production
• Embossing for Texture and Improved Design (emboss over mechanical keys or emboss a company logo)
• UV Protection for Outdoor Use
• In-Mold Decorated Overlays and Plastic
• …and more.

• Small Format Advertising Signs (indoor and outdoor)
• Membrane Switch Overlays
• Control Panel Overlays
• …and other graphic panels

• Integrate Multiple Silicone Colors
• Choose From a Variety of Materials
• Print Multiple Colors for Text and Legends
• Laser Etched Legends for Back Lighting
• Coating Options for Increased Durability
• Chemical and Environmental Resistance
• Liquid Injection Molded Products
• Plastic Key Caps
• Metal Keypads - Durable Construction, Custom & Stock Designs
• Carbon, Gold, and Copper Contacts

INTRODUCTION

SILICONE RUBBER BENEFITS

• Resistance to both high and low temperatures (-55° C to 250° C)
• Minimal noise generation due to soft and elastic contact structure
• Minimal abrasion and high resistance to SO2 and oxidation even in heavy humidity

• Design both tactile and linear feedback
• Translucent color is excellent for backlighting
• Cost effective
• Multi-color designs easily accommodated
• Water and contamination resistant

Dictionary of Terms Used

Basic Key Considerations

Key design will vary with the functional and aesthetic requirements of the application. It is possible to mold a key in almost any shape and to fit almost any configuration. It is important to remember that the key shape will affect the feel of the key. While a circular shaped standard key will have a consistent feel across the entire surface a half moon shaped key will respond different depending upon where the key is pressed.

Once you have decided upon a key shape and layout; the next item to consider is the method for marking the rubber and creating legends. There are three common methods for marking keypads; printing, laser etching, and plastic key caps.

Printing

Printing is the most common method of marking rubber. The rubber is fixtured to flatten the key top then screen printed. There is no limit to the number of colors available. The arc of the key top determines how far printing must be set back from the edge of the key.

There are currently several options available for improving legend life with printed rubber.

• Plastic Key Caps – custom molded clear plastic is adhered over the legend or molded into the rubber.
• Oil or Epoxy Coating – coating is deposited on the top surface of the key over printing, available in matte, semi-gloss, or gloss finish.
• Drip Coating – drip coating can be hard or flexible. It adds a glossy layer over the key top. It can not be used on some keys with sharp angles. Hard coatings are subject to cracking if the key has large surface areas.
• Parylene Coating – offers the highest level of protection for a non-plastic coating. Parylene bonds to the rubber at the molecular level.
  

Laser Etching

Laser etching is especially well suited for applications where the keypad is backlit. Etching typically involves three production steps.

1) Translucent rubber (any color) is sprayed with a translucent base coat ink which will be the legend color that is visible to the user.

2) Rubber is sprayed with an opaque top coat ink which will be the overall color of the keypad.

3) The top coat of ink is laser etched away using high speed etchers to reveal the base coat.

Alternatively, you can decide to use a single translucent or opaque rubber ink and laser etch the legends revealing the color of the rubber that is used.

Plastic Key Caps

The longest lasting legend type is custom molded plastic. Plastic legends will not wear out. Many cell phone keypads are designed with plastic keys over rubber.

Functional Design Considerations

Snap Ratio & Tactile Feel

The snap ratio of a keypad determines the tactile feel experienced by the user. The recommended snap ratio for designers to maintain is 40%-60%; if dropped below 40% the keys will lose tactile feel but have an increased life. Loss of tactile feel means the user will not receive a ‘click’ feedback during actuation.

Snap ratio is calculated by taking the [ACTUATION FORCE (F1) – CONTACT FORCE (F2)] / ACTUATION FORCE (F1).

The membrane shape and the size of any rubber key mat can be designed to achieve a variety of actuation forces and tactile responses. Most applications require a positive tactile feel and a long life. With these requirements, an actuation force of 125-150 grams and an accompanying snap ratio of 40%-60% is a good recommendation. Other combinations can be achieved by changing the contact stroke, actuation force, key shape and material hardness. RSP works with customers to achieve the specifications required. Always remember to specify a higher actuation force for wider or taller keys.

Reducing Rocking Action

A common problem with rubber keypad design is the rocking action that can occur when a key is pushed. Rocking action can reduce the life of the keypad, make actuation difficult for the user, and cause other problems. The following suggestions will assist in reducing this problem.

• Add stabilizing posts on base of key
• Keep key stroke as near 0.8mm as possible
• Keep web length to a minimum
• Keep web angle close to 40°
• Actuation force of 80-150 grams for keys 10-15 mm high and 150-175 grams for keys 15-25mm high

Return force should also be set at 30-35 grams to ensure that keys do not stick.

Switch Life

The web design and the durometer of the rubber are the two factors that affect keypad longevity most. The design should reduce stress on the rubber if long life is desired. Using higher durometer silicone, increasing the actuation force, or increasing the stroke will all decrease the keypads life.

Rubber Hardness

Rubber hardness for a keypad can vary between 30 and 70 durometer (Shore A). Typically, most keypads are built between 40 and 60 durometer.

Minimum Key Height

For any design, calculate the minimum key height as follows; Keypad Base Thickness + Bezel Thickness + Stroke of Key + 0.5mm.

Contacts

The carbon pill is the most common contact because of its long life (>10 million actuations) and low resistance (<100W). The pills are usually circular with diameters ranging from 1.5-10mm and thickness from 0.4-0.6mm. Oval shaped pills are also available in a variety of sizes.

Printed carbon contacts are available in any shape however thickness is typically only 10-20 microns and resistance around 800W.

Dipped carbon contacts offer a compromise with any shape being available and contact resistance of <300W.

Printed Circuit Board Design

Rubber key mats themselves are very reliable in operation. However, when considering a PCB design, the environment in which the keypads are used must be considered to ensure that the complete switching unit is reliable.

The choice of plating for the board is probably the most critical factor with the cheaper tin/lead solder boards not being recommended.

Gold plating over nickel plating is the preferred choice for board design with a recommended layer of 30-50 microns of gold and 100-200 microns of nickel giving a contact resistance of <100W.

Nickel plating is the next best option and the most commonly used; nickel offers good reliability and is more cost effective than gold over nickel. A plating level >200 microns is recommended for the best overall performance.

When designing shorting pads, always attempt to insert as many shorting paths as possible to increase switch reliability and ensure the pad size is never smaller than the carbon pill by a minimum of 1.25 times.

Flexible Printed Circuit Design

Rubber keypads are typically used with printed circuit boards. However, many rubber keypads are also used with flexible printed circuits. Flexible circuits can be made of polyester or copper.

Mechanical Drawings

RSP can estimate most rubber projects with a 2D drawing that shows the number of printed colors and the number of rubber colors that are used. When your design moves to production or if you need to receive more accurate pricing you should try to include the following information if applicable:

Typical Keypad Specifications

Custom Quality Plastic Injection Molding

• Design/Engineering : Our engineers in China can rebuild plastic models from a sample or work with a two dimensional drawing. Often this engineering is free with your tooling order.
• Prototypes : Quick turnaround options for rapid prototypes produced domestically or in China.
• CNC : Confirm your design with the fastest and most economical method available. CNC units are produced from a slab or bar stock and can be machined from a variety of materials.
• Mold Fabrication : We can have your mold built in China for the lowest price available with quality and accuracy guaranteed. We can then transfer your mold to a United States production facility for local molding.
• Molding : RSP provides low cost manufacturing at an ISO certified factory for low, medium, and high volume production.
• Value Added : RSP offers a variety of services including membrane switches, rubber molding, PCB and more... We can supply you with multiple products, perform initial assembly steps, or integrate multiple products into a single part.
• Software : SolidWorks, AutoCAD, Pro-E or we can provide a model from your sketch or drawing.

Cost Saving Example : A current customer was purchasing an off-the-shelf plastic enclosure and spending a lot of time and money modifying the units to get the product to market. The customer's local supplier quoted the tooling at $18,000 for 3 plastic pieces. The same plastic tooling cost our customer $8,500.

Value Added Example : A customer was ordering plastic injection molded parts and mounting several labels and a membrane switch on the unit at their facility in Milwaukee. RSP was able to supply the customer the plastic, membrane switch, and labels together on the unit eliminating 3-4 minutes of assembly time from their production line and saving them thousands of dollars a year! Call us today to see how affordable and easy plastic injection molding projects can be when you work with a US factory manufacturing in China.

RSP is your trusted source for plastic injection molding, rubber keypads, membrane switches, turn-key assemblies and more. Our engineers and offshore production facility can design, rapid prototype, and produce your plastic parts.

RSP has over 50 years of manufacturing and design experience. We work closely with the customer, the engineer and the production team to make sure every project is completed to specifications and on-time.

If you need additional information please contact us directly at (414) 546-4417.

INTRODUCTION

This design guide is intended to offer basic information on plastic design and offer guidelines for you to follow as your project develops.

Plastic injection molding is the primary process for manufacturing plastic parts. Plastic is a very versatile and economical material that is used in many applications.

Injection molding involves taking plastic in the form of pellets or granules and heating them until melted. The melted plastic is forced into a split-die mold (chamber) where it is allowed to cool. The mold is opened and the part is ejected.

ABS (acrylonitrile-butadiene styrene) is the most common molded plastic. ABS possesses outstanding impact strength and high mechanical strength which makes it suitable for use in tough consumer and industrial products.

PROTOTYPING

There are several options for prototyping plastic designs. Our engineer can supply you a part very quickly using fused deposit modeling (FDM). For a more robust sample the factory can produce CNC parts in 2-4 weeks. CNC parts can be done in a variety of materials, colors, and finishes and are structurally stronger than most other methods of modeling.

DESIGN CONSIDERATIONS

Design Options
Standard tooling charges often includes 3D modeling. We can build the design based on your 2D drawing or a sample part. Some customers using off the shelf plastic parts find that the design flexibility, reduced assembly time (snap together pieces, custom fit enclosures) and/or reduced processing costs (modifying the off the shelf option) make a custom plastic part as affordable as or cheaper than generic solutions. Call us and let us know what part you are currently using and we can price a custom molded piece and discuss how to save you time and money.

Draft
Plastic parts need to be designed with a taper or draft in the direction of mold movement to allow the part to eject from the mold. Since plastics shrink when cooled, it is common for parts to shrink to cores.

• Draft angle of ½ degree is regarded as the minimum for most applications
• Common draft angles are 1 ½ - 2 degrees

Ribs
To increase the stiffness and rigidity of a part that is load bearing many designs include ribs. Ribs are a practical and economical method of increasing the structural strength.

• Rib thickness should be less than wall thickness. A rib thickness of 60% - 80% of nominal wall thickness is recommended.
• The maximum height of a rib is 3x’s the nominal wall thickness of the part. The minimum spacing between ribs is 2x’s the nominal wall thickness.
• To improve strength, increase the number of ribs rather than increasing the height of the ribs.
• When thicker ribs are needed, the ribs should be ‘cored out’ from the back so that the wall thickness remains uniform.

Holes
Holes are a common feature of plastic molding. Core pins are used that protrude into the mold cavity to create the opening. Through holes are easier to produce than blind holes which do not go through the entire part. Blind holes are created by using a pin that is only supported on one end. Pins used for blind holes are susceptible to being deflected and pushed off center by the pressures of the molten plastic material during molding.

• The depth of a blind hole should be about 2x’s the diameter of the core pin up to 3/16" and up to 4x’s the diameter of the core pin for dimensions greater than 3/16".
• For every cored or molded hole in plastic there will be a weld line. The weld line is caused by the flow of the melted plastic around the core pins. Weld lines are not as strong as the surrounding plastic material. Weld lines may also detract from the appearance of the plastic. This can be eliminated with a more functionally stable design.
• Whenever possible, design features should be incorporated in the same direction of the mold opening so that cam action can be avoided. Cams create undercuts in the plastic and are retractable so that the part can be ejected.

Bosses

• Wall thickness around a boss design feature should be 60% of the nominal part thickness if the part is less than 1/8" thick.
• If the nominal part thickness is greater than 1/8", the boss wall thickness should be 40% of the nominal wall thickness.
• The height of the boss should be no more than 2 ½ x’s the diameter of the hole in the boss to avoid sink marks and surface imperfections.

Finishes
If the part is not visible to the user you will probably choose the standard finish. There are several items to consider when picking a finish.

Polishing

Texturing

There are many reasons to use plastic in your design and many of our customers switch parts from metal to plastic.

• Decrease piece price: after initial tooling the piece price can be substantially lower with plastic.
• Eliminate secondary operations: plastic can be colored and textured in the molding process. Several metal parts can sometimes be replaced with 1 plastic piece.
• Reduce product weight: plastics weigh less than metals and can make it easier for the user or assembly team to work with and it also reduces shipping costs.
• Increased structural strength: in some applications a well designed plastic piece is stronger than a metal piece. Plastic can have ribs and bosses built in eliminating secondary procedures needed with some metal.
• Increase product life: metals are much more susceptible to environmental degradation. Most plastic has greater chemical resistance than metal.

• Print a Variety of Stunning Graphic Images.
• Mass Customization with Assorted Images Using a Single Mold.
• Lenses, backlit, EMI/RFI shielding.
• Integrated Keypads.
• Surface Textures & Hard Coating (Scratch Resistant).
• In-Mold Decoration.

The first step in IMD is very much like printing a membrane switch overlay. The image is printed on high quality polycarbonate using special heat resistant inks on the first or second-surface. Good quality film is essential, with controlled gauge (thickness), clarity, and minimal internal stress.

The printed film then needs to be formed to fit the profile of the injection mold. The image is either thermoformed or vacuum formed to the final shape.

Once the printed part is formed, it is trimmed to fit the mold cavity. It is then manually or robotically inserted into the plastic injection mold. The mold closes to hold the part in place and the melted polymer is injected, coming in contact with the back of the printed image. The polymer fuses onto the back of the film, and the materials are bonded together. The part is now complete and no post-processing is required

Polycarbonate, Acrylic, ABS, and blends are the most common plastics used.

RSP is the trusted supplier to hundred's of customers around the world.

In 50 years of manufacturing we have gained the experience and expertise that separates us from our competitors.

Our factory, RSP Electronics Ltd, is located in Huizhou, China. It is a high quality facility and we service a variety of industries. Our in house capabilties include rubber and plastic molding, membrane switches, printing, and assembly. Having our own dedicated facility allows us to control product quality, offer excellent pricing, streamline manufacturing, reduce lead times and produce very high quality parts. No job is too big or too small.

What Makes Us Different

• Partner: RSP is a design and manufacturing partner that is invested in your products success. We have a proven record of bringing the customer vision to life.

• Quality Assurance: RSP operates its own controlled facility in China. Whenever possible, we manufacture and assemble the products in-house using US manufacturing and quality standards. RSP also operates an independent quality control and engineering office in Shenzhen, China. This independent office allows us additional quality control at our own facility as well as the ability to quickly source and inspect any items needed from other suppliers. Our staff from the US are at the factory most of the year and as needed for key project developments. RSP works closely with the customer to ensure that before units are shipped that they are fully tested and that every unit matches our customer’s specifications.

• Intellectual Property Protection: Your ideas and intellectual property are protected at RSP. Many of our customers have proprietary software or design that demands tight controls. Our facility is isolated in a secure business park and inventory is tightly controlled. RSP has the ability to isolate a production facility floor to maintain the highest level of security possible.

• Cost Savings: RSP operates its own facility in China ensuring that our pricing is extremely competitive. Many of our competitors shop jobs around and seek the lowest pricing in order to maximize their own profits. Often this results in poor quality, project delays and price increases. At RSP, our number one priority is understanding the needs of the customer. Once we understand your needs and the product requirements we can offer you an accurate and fair price.

  

In addition to our own factory, we have associates in large manufacturing centers in China available to locate, qualify, and inspect potential vendors for many other products or items needed in a turn-key assembly.

Every customer is welcome to visit our factory and tour the facility. Our associates meet you in Hong Kong and comfortably escort you to our factory quickly.

RSP is a family owned and operated business offering outstanding service.

Call us to find out if our expertise is a good match for your strategic contract manufacturing needs.

• Digital Resistive Touch Screen : This type of touch screen is sometimes referred to as the X-Y matrix touch screen. The typical border width is at least .25”. Digital resistive touch screens operate by decoding or measuring a direct resistive circuit.
• Analog Resistive Touch Screen : This type of touch screen is designed for ‘pen recognition’ applications and other applications where a high resolution is required.
• Capacitive Touch Screens : All-glass touch screens with a transparent metallic conductive coating. When a finger touches the screen and draws a small amount of current to the point of contact, creating a voltage drop.

• Control and Automation Systems
• Public Information Displays
• Customer Self Service
• Machine Operation
• …and many more.

Resistive Touch Screens - Product Data Sheet

A touch screen is a machine interface that is sensitive to touch. Many cash withdrawal (banking) machines utilize touch screen technology. The touch screen is a clear panel that mounts in front of an LCD display. We can print legends or other text directly on the glass if needed. RSP supplies touch screens and LCD assemblies.

Standard touch screens are rigid (glass) but they can also be flexible. The operating temperature is approximately -10ºC – 70ºC (14ºF – 150ºF).

Digital Resistive Touch Screen

This type of touch screen is sometimes referred to as the X-Y matrix touch screen. It has a projected life of 1 million actuations.

The typical border width is at least .25”. Digital resistive touch screens operate by decoding or measuring a

direct resistive circuit. There are four layers;

1. Top polyester layer coated with a conductive coating

2. Adhesive spacer

3. Glass layer coated with a conductive coating

4. Adhesive layer on the backside of the glass for mounting.

Advantages

• No false actuations
• Low cost
• Easily adapted tp various sizes (1”x1” minimun ) and configurations
• Able to be sealed to NEMA-4 specifications

Disadvantages

• Limited number of touch points
• Mechanical wear, top layer can be scratched
• Glass layer can break

To produce digital resistive touch screens conductive coating is either etched away or selectively applied to form rows on one layer and columns on the opposite layer. When assembled, the rows and columns form a matrix of switches. The location of each switch is permanent. The resolution of the touch screen depends upon the number or rows and columns specified.

Analog touch screens have one layer that carries the X axis and one layer that carries the Y axis. The axes are determined by the orientation of bus bars printed on two opposite edges of each layer. Both axes must remain perfectly linear in order for the touch screen to function properly. When the two conductive coated layers are placed together it forms a single switch. An analog switch is activated no matter where the screen is touched. The controller detects the location of the touch based on the voltage drop sensed in each layer at the point where they make contact.

Unlike digital touch screens which require a pin connector for each row and column, analog models can be attached to the controller with either a 4-pin or 5-pin connector. The standard 4-wire analog touch screens have a projected life of approximately 1 million actuations. Typical border widths are .15”. There are four layers:

1. Top polyester layer coated with conductive film

2. Adhesive spacer

3. Glass layer coated with a conductive film

4. Adhesive layer for mounting

The 5-wire analog touch screens have a projected life of approximately 35 million actuations.

Typical border widths are .25”. There are six layers:

1. Top polyester layer coated with conductive film

2. Adhesive

3. Polyester spacer

4. Adhesive

5. Glass layer coated with a conductive film

6. Adhesive layer for mounting

Printed spacer dots on the glass layer are used for controlling the actuation force and to keep the

conductive layers from premature contact.

Advantages

• No false actuations
• 4096 x 4096 touch points
• No stylus needed, operates with a gloved finger
• Able to be sealed to NEMA-4 specifications

Disadvantages

• Maximum transmissivity of 80%
• Mechanical wear, top layer can be scratched
• Glass layer can break

Analog Resistive Touch Screen

This type of touch screen is designed for ‘pen recognition’ and other applications where a higher resolution is required than is feasible with a digital resistive touch screen.

Analog touch screens have one layer that carries the X axis and one layer that carries the Y axis. The axes are determined by the orientation of bus bars printed on two opposite edges of each layer. Both axes must remain perfectly linear in order for the touch screen to function properly. When the two
conductive coated layers are placed together it forms a single switch. An analog switch is activated no matter where the screen is touched. The controller detects the location of the touch based on the voltage drop sensed in each layer at the point where they make contact.

Unlike digital touch screens which require a pin connector for each row and column, analog models can be attached to the controller with either a 4-pin or 5-pin connector.

4-wire analog touch screens have a projected life of approximately 1 million actuations. Typical border widths are .15”. There are four layers:

1. Top polyester layer coated with conductive film
2. Adhesive spacer
3. Glass layer coated with a conductive film
4. Adhesive layer for mounting

Advantages

• No false actuations
• 4096 x 4096 touch points
• No stylus needed, operates with a gloved finger
• Able to be sealed to NEMA
  

Disadvantages

• Maximum transmissivity of 80%
• Mechanical wear, top layer can be scratched
• Glass layer can break

• No false actuations
• 4096 x 4096 touch points
• No stylus needed, operates with a gloved finger
• Able to be sealed to NEMA
• Rated for 35 million actuations
  

Disadvantages

• Maximum transmissivity of 80%
• Mechanical wear, top layer can be scratched
• Glass layer can break

• System/Architecture Design
• Electronic Circuit Schematic Design
• PCB Layouts
• Prototype Fabrication and Functional Testing

• Automated High Volume Assembly
• High Density, Complex SMT
• In-Circuit Test (ICT), Functional Test (FT), Burn-In
• RoHS – Lead-Free Manufacturing
• SPC and Process Control Systems
• Certifications: ISO 9001, ISO 14001, TS 16949, QS9000, BABT Certification

RSP has industrial lasers with cutting speeds as fast as 20 inches per second. RSP has the ability to laser cut plastics, polyester, polycarbonate, rubber, laminates, acrylics, and more

We have developed strategic alliances with several laser shops to offer you the lowest cost high speed gantry laser cutting and precision laser engraving.

If you are concerned about whether your particular material is laser 'friendly' call us or send us a sample of the material you need cut and we will test it for you free of charge.

Many of our current laser customers came to us with projects that other laser job shops could not handle well or at all. We work with our clients, our laser manufacturers, and our software team to develop solutions and get the job done.

• Custom Over Molding
• Turn-Key Manufacturing
• Prototypes
• Cutting, Stripping, Splicing
• Tinning (corrosion protection)
• Terminating, Connectors, Component Installation
• 100% Electrical Testing
• After Market Automotive
• …and more.

At RSP, we work with the customer to provide the highest quality product at the best available price. We have in-house plastic molding, silicone molding, printing and assembly capabilties.

Call us now to find out how RSP can help you!

RSP offers a wide variety of EL lamp (electroluminescent) designs and constructions to meet your requirements.

Common colors include:

• Blue/Green
• Yellow/Green
• White
• Blue
• Orange

Call today to find out how we can help with your EL lamp and other production needs.

Plastic & Silicone Molding

• System/Architecture Design
• Electronic Circuit Schematic Design
• PCB Layouts
• Prototype Fabrication and Functional Testing

1. Customer had a prototype unit designed and built in the USA. It was a great functional product but not designed for mass production. RSP engineers studied the sample,updated the design to reduce assembly and parts prices, developed Gerber files for approval, and supplied the customer with prototypes for testing and approval.
2. A product on the market used an expensive after market wire harness for a new product. The production quantity was growing and the cost of the after market product was becoming prohibitive to their continued growth. RSP engineers were able to study the current product, re-engineer it, and produce a custom piece with improved performance at a substantially lower price point.
3. A customer needed an outdoor design for a hand held remote control. RSP engineers have a lot of experience with this type of requirement. Using our experience and studying the customer design requirements resulted in a NEMA-4 contstruction enclosure and silicone rubber user interface that withstands the outdoor elements.