Next Vility will share the process of flex circuits making from one of their customers.
Flex circuits made at BIT go through a variety of printing, finishing, and assembly processes. To stick with the same example, membrane switches go through the engineering and graphics departments first. A membrane switch often includes many layers, not just circuitry. The top layer of a membrane switch is a graphic overlay. The graphic overlay could be screen or digitally printed. It is common for the graphic overlay layer of the membrane switch to be digitally printed while the electrical components are screen printed, but many manufacturers prefer to apply screen printing.
The graphics department also works with the screen printing department to create the necessary films for printing. Once the films are complete, the design starts to get printed layer by layer. Precision printing presses have CCD registration screen printing machine or 4-post to create consistent and precise fine line circuits. Some graphic overlays will still need to be printed using a screen printing press. Specialty inks like metallics and medical-grade coatings are not compatible with a digital printing press. automatic screen printing equipments are used for any graphic overlays that have gradients and complex color designs.
Once the circuitry and any other layers of the product get printed, they go to the finishing department. It is common for multiple switches to be printed on one sheet. Once the design gets to the finishing department, they get laminated if needed and also apply our high precision CCD regulation die cutting machine .
Once the components are finished, the assembly team begins to add the other features. They can add things like metal domes, LEDs, and connectors.