Full-Scale Production

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.

Some advantages of screen printing 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 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.

Digital printing eliminates many of the steps of screen printing, including screen making, ink layering, curing, and drying. It is ideal for small to medium-sized orders of graphic overlays, gauges, signage, and other user interface products.

Screen and digital print processes can be combined, further expanding our product offerings and production flexibility.

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 Plotter Cutting

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.

Quality Inspections

Producing a consistent and high-quality part is how we measure success at Butler Technologies. We have a robust quality department that is involved in every step of the manufacturing process. Components are inspected for visual conformance, electrical functionality, and strict adherence to customer specifications.

We are prepared to meet your standardized inspection requirements. We have experience with many industry quality systems. Check out our Certifications & Approvals page to learn more.

Quality Inspection Systems

FAI
PPAP
Customer Specified Requirements