This one is for Melanie if you have time.

[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,

[Luciano]

Hi Sphere,

Yesterday I posted a link of a company in the UK.

The same company has another web site:
http://www.customdesigntechnologies.com

They have a service called "customAssembly".

Try to contact these people and see If they are willing
to take some risks together with you. (Joint venture).
http://www.customdesigntechnologies.com/id29.html

I am sure that they have already an eclosure with keypad
that will fit your needs, so the initial costs will be low
for them. Later on, if the product sells well, a new
enclosure with new keypad is always possible.

Good luck with your project!

Best regards,

Luciano

[Melanie]

>> So that was a production one rather than a protoype.

Prototype or Production, the process is very much the same here. In the case of the facia, we use a small one-man silk-screener who works out of a garage in his home. Half a dozen new labels for a prototype he'll do for free on the basis we give him many thousands worth of business over the year. Likewise we have a good relationship with the metal-basher who knows that prototypes lead to production quantities later down the line. Again, it's time to cultivate relationships with suppliers, and to stick by them because they rely on you as much as you on them. We spend for example about $250k with one small sheet-metal shop. Yes, I could halve that figure by switching the work to China, but he's got kids in school and a morgage to pay too and relies on my work. On the other hand, by keeping him in business I've got someone twenty minutes down the road that I can say "I need this in a hurry" hand him a quick scribble done on the back on an envelope and I'll know he'll work all night to do it.

[Ioannis]

Hi Melanie. If it is not too much trouble, a couple of photos of the sandwitch assembly would be helpful.

Thanks,
Ioannis