Full-Scale production is the complete manufacturing process that takes your product from design through printing, fabrication, and final assembly, ready for deployment at scale. Every stage is managed in-house under ISO-certified quality systems, ensuring consistency, quality, and accountability from concept to completion.

Butler Technologies, Inc. offers full-scale production, taking your products from design through printing to assembly. Whether you require graphic overlays, membrane switches, simple labels, or fully functional printed electronics, we are capable of meeting your needs. Our capabilities include:

Screen Printing
Digital Printing
2D Cutting
Value-Added Assembly
Quality Inspections

Screen Printing

Screen printing is a technique that uses mesh to transfer ink to a substrate. Print screens are prepared using stainless steel or high-tension, low-elongation polyester mesh. The desired image or pattern is created with light-reactive emulsion, capillary film, or a combination of both processes.

Depending on customer requirements, UV-curable, solvent-based, plastisol, and water-based inks and coatings are used. Special effect inks and surface finishes are used for visual and tactile enhancement of the finished product. Conductive and dielectric insulating inks are utilized in our membrane switch and printed electronic products.

Key advantages of our screen printing services include:

Better color accuracy and matching
Able to print fluorescents, metallics, and chrome colors
Ideal for larger order quantities

Digital Printing

Digital printing is a technique that transfers digital files to a substrate. We offer multiple options for digital printing, including the SwissQprint Impala 3, Acuity Advance HS Printer, and the Roland Sol-Jet XC-540. Most options can handle large-formatted projects, but printed designs are typically restricted by the size of the substrate material.

Our digital printing services are well-suited for projects requiring detailed graphics, color variation, a fast turnaround, or lower-volume production. This method is commonly used for graphic overlays, gauges, labels, signage, prototypes, and other user interface components where design accuracy and visual quality are important.

Screen and digital print processes can be combined to expand service offerings and increase production flexibility. This approach helps balance durability, detail, substrate requirements, and visual finish based on the needs of each application.

To support consistent results, computer-based formulation, spectrophotometer measurement, and transmission densitometer tools are used to precisely match and control color throughout the print process. We hold ourselves to Delta E standards of ≤2.

2D Cutting

Our 2D cutting capabilities enable us to produce gaskets, ESD shields, and flame-retardant insulators to fit almost any application. Whether your application requires closed-cell foam, neoprene, copper, aluminum, polyester, or any variety of materials, we can fulfill your precision cutting needs. Our capabilities include:

Laser Cutting

Laser cutting can generally produce finished cut features within +/-0.002” and cut-to-print tolerance of +/-0.005”.
Laser cutting does not require hard or fixed tooling and is a great help in expediting the prototyping process.

Die Cutting

Tolerance on die-cut features ranges from +/-0.010” on materials 0.020” thick or less to +/-0.015” for materials greater than 0.020” thick.
Typical cut-to-print tolerance of +/-0.010” can be held depending on material thickness.

Drag Knife

An ideal choice for heat-sensitive applications or materials that emit toxic fumes (PVC).
Typical cut-to-print tolerance of +/- .005” can be held depending on material thickness.

Value-Added Assembly

We have the equipment and expertise to handle your assembly needs. From the lamination of adhesives, spacer materials, and overlaminate films to the surface mounting of LEDs and other SMD components, to the installation of Berg and Nicomatic electrical connectors, we have what you need, including:

Ability to handle cold and heated lamination processes.
Both semi-automatic and manual crimping equipment allow the installation of electrical connectors and BERG (2.54mm pitch) and Nicomatic (2.54mm and 1.27mm pitch).
Electrical testing of membrane switches and other printed electronic assemblies is handled using multiple Banair Darren and Dataswitch electrical testers.

Streamline Supply Chains

Butler Technologies can help reduce supply chain complexity through value-added assembly services that bring lamination, connector installation, component mounting, and testing into one controlled workflow. This integrated approach helps reduce vendor handoffs, improve production consistency, and simplify the path from individual components to finished assemblies.

In one medical device project, Butler Technologies helped cut the customer’s vendor count in half through integrated value-added assembly support.

For more details, explore our client case study.

Download Case Study

Quality Inspections

Quality inspections are built into every stage of the manufacturing process at Butler Technologies, Inc. Our team checks components for visual conformance, electrical functionality, dimensional accuracy, and adherence to customer specifications to help ensure consistent production quality.

We also support standardized inspection requirements across different industry quality systems, helping OEMs maintain confidence from first article approval through ongoing production.

Quality Inspection Systems

FAI
PPAP
Customer Specified Requirements

Medical Devices

Industrial Controls

Heavy Equipment & Utility Vehicles

Aut & Marine

Safety & Personal Test Equipment

Energy

Millitary & Defence

Data Centers

Consumenr Foods

White Goods

ISO CERTIFIED QUALITY

Every product meets rigorous quality standards.

On-Time Delivery

Production schedules built to meet your deadlines consistently, from prototype runs through high-volume orders.

Design to Production

Full in-house capability from concept and prototyping all the way through full-scale production, one trusted partner for the entire journey.

Supply Chain Simplified

Value-added assembly services have helped clients reduce their vendor count by up to 50%, cutting complexity, lead times, and cost.

Expert Team

Engineers and manufacturing specialists with deep expertise across medical, industrial, defense, and consumer applications.

Custom Capabilities

Printed electronics, biometric sensors, flexible heaters, and advanced manufacturing capabilities that most competitors simply cannot match.

What does full-scale production include?
Full-scale production includes the key manufacturing steps needed to take a product from approved design to finished parts, including printing, fabrication, 2D cutting, value-added assembly, electrical testing, and quality inspections.
When should I choose screen printing instead of digital printing?
Screen printing is best for larger production runs, specialty inks, durable graphics, and consistent color matching. Digital printing is better for small to medium runs, detailed graphics, faster design changes, and product variations.
What 2D cutting methods does Butler Technologies use?
Butler Technologies uses laser cutting, die cutting, and drag knife plotter cutting to support different materials, tolerances, and production needs.
Can Butler Technologies handle assembly after printing and cutting?
Yes. Butler Technologies provides value-added assembly services including lamination, connector installation, LED and SMD component mounting, and electrical testing for membrane switches and printed electronic assemblies.
How does Butler Technologies support quality during production?
Quality inspections are built into the manufacturing process, including visual conformance checks, electrical functionality testing, dimensional review, and customer-specified requirements such as FAI, PPAP, and CSR.

Full-Scale Production