What is Full Scale Production?

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:

Then show the row of services below (which would be more beneficial if it worked as a jump link):

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.

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.