Graphic overlays serve as the visual interface and primary point of contact for users, so selecting an appropriate material (film or graphic overlay) for your custom graphic overlay (film or graphic overlay) is key to its durability, functionality and overall performance. By considering its intended use, construction criteria, environment, and appearance criteria along with your budget you may find one which meets all these requirements seamlessly; options like polycarbonate film, ABS polyester film or polyurethane could all work as suitable solutions.
Understanding the intricacies of material selection can dramatically enhance its durability, functionality, and appearance – whether you’re a graphic overlay supplier, engineer, designer or product manager; an in-depth knowledge of available materials will enable you to craft products that are both beautiful and long-term solutions.
Graphic overlay materials will be discussed extensively, along with their unique properties and how to select an optimal one based on your specific requirements.
1. Key elements of graphic overlays
Graphic overlays not only add visual appeal, but they also enhance functionality and durability. Three key factors come into play here:
1) Substrate material
The substrate material chosen is key to any graphic overlay’s longevity, feel and appearance; with polyester being two of the more popular choices.
- Polycarbonate: Polycarbonate offers high transparency, dimensional stability and impact resistance – ideal for areas with heavy traffic and wear and tear.
- Polyester: Due to its superior chemical resistance and longevity, Polyester is often chosen for environments exposed to chemicals or extreme conditions.
2) Adhesive layer
An adhesive layer must be added in order for an overlay to securely adhere to its target surface, and may differ depending on factors such as:
- Application surface (e.g., metal, plastic, glass)
- Environmental factors (such as UV radiation exposure, moisture conten,t or chemical use)
- Operational requirements (for instance, frequent user interaction)
3) Surface treatment
Overlays come in different designs and finishes, each providing aesthetic and functional advantages:
- Matte: To soften glare for a subtler look.
- Gloss: Provides a glossy surface to enhance the vibrancy of colors.
- Antimicrobial: Provides added protection from microbial growth – ideal for healthcare environments.
2. Differences between polyester, polycarbonate and acrylic
Comparing the properties of polyester, polycarbonate, and acrylic materials provides insight into their unique advantages for various applications. Here is an in-depth examination of each one, starting with polyester graphic overlays.
1) Polyester graphic overlay
Polyester (PET) plastic is one of the most frequently used plastics, especially as graphic overlay materials. Polyester has become one of the most durable plastics when used as part of membrane switches or control panels; in fact, estimated one million switch actuation cycles before its appearance begins deteriorating significantly.
Polyester graphic overlays are well suited to use in harsh environments due to their resistance to chemicals, temperature extremes, abrasion and more. You can add hard coatings for greater strength and durability of PET graphic overlays – visually ,they feature consistent textures with glossy surfaces for an aesthetic touch.
Polyester graphic overlays are ideally suited for applications subject to heavy use or harsh environments, such as industrial products. But this type of graphic can also be found in consumer goods and medical supplies.
2) Polycarbonate graphic overlay
Polycarbonate (PC) material is often recommended for applications that require minimal flexing, with its estimated lifespan estimated at 100,000 cycles. However, PC graphic overlays offer unique advantages that might make them the ideal solution for your particular use case.
Polycarbonate material is known for its heat resistance and flame retardancy qualities, making it more abrasion-resistant than PET; hard coating can also be used for added surface durability.
PC is an attractive visual and production option over PET, providing several visual and production advantages over PET. PC can be more easily printed (including color matching) and die cut than PET, with various thicknesses, textures and finishes available – an excellent solution if aesthetic appeal is more important than durability in your application. Polycarbonate graphic overlays have found widespread application across industries including aerospace, automotive, industrial and safety products.
3) Acrylic graphic overlay
Acrylic overlays may not be used frequently for graphic overlays, but they’re still useful plastic options to consider. Acrylic is popular due to its transparency and lightness; more transparent than regular glass while weighing nearly 50% less. Acrylic can diffuse or transmit light more efficiently than any other medium while remaining strong so as to provide rigidity for durable displays – it has even found use in industries like medical and automotive settings.
4) PVC graphic overlay
PVC graphic overlays offer the most cost-efficient solution for switches and keypads with short to medium lifespan products due to its moderate performance characteristics and range of textures, finishes, and color combinations. When it comes to graphic cover materials, PVC should always be your top choice due to its economical properties – PVC graphic covers offer cost savings!
3. Choose the right graphic cover material
The selection of an appropriate graphic overlay material depends on several factors. Environmental conditions (temperature and chemicals), usage conditions (indoor and outdoor applications and UV exposure), flexibility, impact endurance, requirements for optical clarity and even personal taste (gloss or matte finish) are typical factors to be considered.
1) Application environment
Indoor/Outdoor Use: Determine whether the graphic overlay will be exposed to outdoor environments (e.g., sun, rain, dust and temperature fluctuations) that could cause harm. For applications exposed to such factors, materials with UV and weather resistance such as polycarbonate (PC) or acrylic (PMMA) might be more appropriate than materials lacking these characteristics.
If the graphic overlay will be exposed to chemicals, oils or solvents – as in an industrial or medical setting – then polyester (PET) or polycarbonate materials with superior chemical resistance such as PET may be recommended as these provide superior resistance against chemical attack.
2) Durability and impact resistance
Heavy Use and Impact Resistance: Before selecting your graphic overlay material, think carefully about its anticipated usage frequency and intensity. For applications involving high frequency impact or high-use applications, polycarbonate (PC) would be a great option due to its very high impact resistance properties.
Scratch Resistance: When dealing with graphic overlays that tend to suffer from wear and tear through frequent keyboard or button usage, the most resistant material to scratching is acrylic or polycarbonate; particularly with additional coating (e.g., anti-scratch coating).
3) Optical clarity and transparency
Wherever visibility and clarity are of utmost importance (for example in displays, backlit overlays or medical devices), polycarbonate or acrylic materials like polycarbonate excel due to their superior optical clarity.
Polyester may provide an economical and effective alternative when visibility of an underlying display is less of an issue.
4) Printability
Printability is an integral step in producing graphic overlays, as it will have a direct effect on their final appearance, readability and functionality. Before selecting materials for printing (screen printing, UV printing or digital printing), consider whether high-quality options exist such as vivid graphics or detailed icons that can be printed accurately onto its surface – polyester (PET) and acrylic make great choices here.
Polycarbonate material prints well but may require special coating or printing techniques in high use environments to maintain durability.
5) Aesthetics and color matching
The overlay should match the design of the device, including color matching, texture, and finish. Consider colors with clear hues and simple designs; these may enhance user experience and have greater visual impacts.
4. Conclusion
Over the years, materials employed have undergone a fundamental transformation. From the early overlays being largely reliant on primitive plastics, today, with the advancements of polymer science over recent years, contemporary overlays are stronger, colorful, and multifaceted than ever. At the forefront is sustainability, which has seen the emergence of bio-based plastics on the market. Some electronic device overlays even come equipped with near-field communication (NFC) chips for added functionality and greater convenience in daily life. Graphic overlays offer limitless possibilities.