INSERT MOLDING solutions

At SiTech, we specialize in insert molding, a versatile process that integrates various materials and components into silicone keypads and parts. This advanced technique enhances functionality, durability, and customization, making it ideal for a wide range of applications, from medical devices to industrial equipment.

Our insert molding capabilities allow us to combine silicone rubber with metal inserts, conductive carbon inserts, and custom backlighting solutions, providing multi-functional products tailored to your design and performance requirements.

Custom Backlighting Solutions with Integrated Light Blocking

One of the most sought-after applications of insert molding is the integration of custom backlighting solutions. Backlit keypads are essential in environments where visibility is critical, such as control panels in low-light or nighttime operations. At SiTech, we take backlighting a step further by incorporating custom light-blocking features directly into the silicone keypad, preventing light from spreading from one key to another.

Our proprietary molding process ensures that the light is directed only where it’s needed, creating clear and well-defined illumination. This allows our customers to avoid the complexities of designing their own light-blocking systems, reducing production costs and ensuring optimal light distribution across the keypad.

With SiTech’s custom backlighting solutions, you can achieve:

• Precision light control: Avoid light leakage between keys.
• Uniform illumination: Consistent and even lighting across the keypad.
• Design flexibility: Integration of light pipes and LED windows for specific illuminated keys or symbols.
  
  
  

Whether you need full backlighting or selective illumination for specific keys, our insert molding process ensures that your lighting components are securely embedded for long-lasting performance.

Conductive Carbon Inserts for PCBs

Our conductive carbon inserts provide reliable electrical contact for PCB-based keypads. These inserts are molded directly into the silicone, ensuring precise conductivity and durability. They are ideal for applications where responsiveness and accuracy are crucial, such as in medical devices and consumer electronics.

Benefits of conductive carbon inserts include:

• Reliable conductivity: Ensures consistent electrical contact when keys are pressed.
• Durable design: Withstands repeated use without loss of performance.
• Integrated seamlessly: Reduces the need for additional components or assembly steps.
  
  
  

Metal Inserts for Added Rigidity and Altitude-Related Stability

For applications that require additional structural support, SiTech can incorporate metal inserts into the silicone components. These inserts enhance the rigidity and durability of the keypad, making them ideal for environments where mechanical stress, impact, or changes in altitude are a concern.

In sealed keypad assemblies, variations in altitude can cause the expansion of gases within the assembly, potentially leading to swelling or deformation of the silicone components. Utilizing metal inserts helps to prevent the expansion of the keypad in such conditions by providing a rigid framework that maintains the integrity and shape of the keypad.

Metal inserts provide:

• Enhanced mechanical strength.
• Reinforced tactile feedback.
• Environmental sealing for protection against dust and moisture.
• Stability against altitude-related gas expansion, ensuring the keypad remains functional and intact in high-altitude environments.

This makes metal-reinforced keypads perfect for military, aviation, and industrial applications where both durability and environmental stability are essential.

Advantages of Insert Molding

Insert molding offers several advantages over traditional assembly methods:

• Streamlined production: Multiple components are molded into a single part, reducing the need for post-production assembly.
• Increased durability: Components are securely bonded to the silicone, offering enhanced resistance to wear and environmental factors.
• Custom light-blocking: Integrated light-blocking technology prevents light from spreading between keys, eliminating the need for additional design elements.
• Metal inserts: Provide stability in sealed assemblies, especially in varying altitudes.
• Cost-efficiency: By eliminating additional assembly steps, insert molding reduces production time and costs, particularly in high-volume applications.
  
  

Proven Applications

SiTech’s insert molding solutions have been successfully implemented across a range of industries, providing enhanced functionality for products such as:

• Medical device keypads with integrated backlighting and conductive carbon contacts for PCBs.
• Industrial control panels with metal inserts for added rigidity and environmental protection.
• Military and aviation equipment designed for high-altitude environments, combining backlighting, metal inserts, and protective features.
  
  

Why Choose SiTech for Insert Molding?

At SiTech, we combine decades of experience in silicone injection molding with cutting-edge insert molding technology to deliver custom solutions that meet the highest standards of quality and performance. Our expertise in custom backlighting, conductive inserts, and metal reinforcements ensures that your product is not only functional but also optimized for durability and efficiency, even in challenging environmental conditions.

For more information about our insert molding capabilities or to request a quote, contact SiTech at 757-887-8488 or email sales@sitech-corp.com.