This one is for Melanie if you have time.

[Luciano]

Hi,

Did you try here?
http://www.customkeypads.co.uk

Best regards,

Luciano

[Sphere]

Yes I did and they where the only one to reply.

Sphere.

[Melanie]

First, ask yourself "do I actually NEED a MEMBRANE keypad or can I get away with another more intuitive solution?".

Here's an example picture of 3 Buttons, LED, IR Receiver plus LCD done as a prototype 'on the cheap'. It looks like a membrane but it isn't. It's actually all standard PCB mounted with the LED and Buttons mounted on the reverse side of the thru-hole-plated PCB.

If it's prototyping or a small production run, then membrane is not the way to go unless you've got a budget (preferably with someone elses money). Once you're sure, then you can go that route, but once you've discovered how inexpensively you can make things using standard PCB's (eg in bulk the switches are like UK 3.5p/US 7 cents each!!!) you may not want the membrane route. Really, that's only a mass-production consideration.

[Sphere]

Im building this with the possibility to sell. So I wanted a finished product to show to suppliers. So thanks for your input and your time.

Sphere...

[keithdoxey]

Here's an example picture of 3 Buttons, LED, IR Receiver plus LCD done as a prototype 'on the cheap'. It looks like a membrane but it isn't. It's actually all standard PCB mounted with the LED and Buttons mounted on the reverse side of the thru-hole-plated PCB.

Very neat Melanie

You forgot to mention the custom faceplate.... aka mounting frame for holding 4 RJ45 modules

What was the fascia made from ?
Is it a screen printed plastic overlay or printed paper behind plain plastic.

[Melanie]

Well spotted Keith. Those RJ45 faceplates make great LCD and/or keypad bezels!

The fasica is two-colour reverse screen printed on flexible clear plastic with a self-adhesive backing applied onto the print side. This means the User can't scratch the print. Any local Screen Printer worthy of the name can handle that with ease.

The fasica fits over an Aluminium (or mild steel) plate which in turn drops into the 4xRJ45 module aperture. This plate has all the cut-outs for the LCD, Switches, LED etc and contains integral threaded pillars onto which the PCB secures from the other side. Again, the manufacture of this plate wouldn't tax the talents of any sheet-metal basher.

If anyone is unclear from the description, I'll pull one out and photograph it if there's any interest.

[keithdoxey]

Well spotted Keith. Those RJ45 faceplates make great LCD and/or keypad bezels!

I have used red perspex to use one to mount LED displays and IR sensors

The fasica is two-colour reverse screen printed on flexible clear plastic with a self-adhesive backing applied onto the print side. This means the User can't scratch the print. Any local Screen Printer worthy of the name can handle that with ease.

So that was a production one rather than a protoype.

The fasica fits over an Aluminium (or mild steel) plate which in turn drops into the 4xRJ45 module aperture. This plate has all the cut-outs for the LCD, Switches, LED etc and contains integral threaded pillars onto which the PCB secures from the other side. Again, the manufacture of this plate wouldn't tax the talents of any sheet-metal basher.

If anyone is unclear from the description, I'll pull one out and photograph it if there's any interest.

Description is perfect but photos are always nice

[Archangel]

Hi Sphere, another resource you may have overlooked is your local sign shop.
They have computer graphic mylar tape cutters that can make any design you can think up. Prospective manufacturers are aware of the cost of custom parts like the keyboard you want, but they are kind of short sighted as to your vision of a product. You can make the simulated membrane keypad and present design of production model along with estimates of setup costs, UNLESS, Unless you intend to be the manufacturer too. Me, I would be happy with my 3 percent or whatever the market is now and move quickly to the next Million seller, and leave the headache of marketing and manufacturing to them,