Polycarbonate Overlays

Specialty Printing & Processing custom designs and fabricates polycarbonate (Lexan) overlays that are ideal for recessed moldings, switch assemblies, and front panel graphics. We meet any Lexan overlay design requirement such as backlighting, panel cut-outs, and harsh/hazardous environmental conditions. Selective or full surface texturing options are available for hard coats as well as aesthetic enhancements.

With conventional screen and digital printing processes, Specialty Printing fabricates a wide variety of polycarbonate overlays for production quantities ranging from one piece to thousands. Most overlays are produced by printing on the second surface (on the back) to protect the image and utilize the added effects provided by the material surface conditions (matte, velvet, gloss, etc.).

Custom Overlays Include:

  • Polycarbonate (Lexan) overlays
  • Control pad overlays
  • Polyester overlays
  • Graphic overlays
  • Membrane switch overlays

Polycarbonate (Lexan) Overlay Specifications

Material Thickness
Active Surface: 0.007″ to 0.010″
Non-Active Surface: Up to 0.020″
Sheet Sizes
Capable of up to 24″ x 48″
Standard Sheets: Up to 20″ x 28″
Surface Condition Options
  • Clear
  • Matte
  • Brushed
  • Velvet
  • Suede
  • UV Clear
  • Tamper Evident
  • Hard Coating (Scratch Resistant)
Full range of adhesives to meet demands of:

  • Full or selective adhesive coverage
  • Low/High surface energies
  • Textured surfaces
  • Smooth surfaces
  • Rough surfaces
  • Adhesive with spacers included
  • Pressure sensitive backings
Protective film over-laminates
Display Windows
Special Options
LED/LCD Display Windows

Process Equipment

Screen Printing Equipment
M & R 5296 Patriot Screen Printing Press
Sias 4052 Screen Printing Press
Sias 3047 Screen Printing Press
American Cameo 2030 Screen Printing Press
Pad Printing Equipment
TampPrint Pad Printer
Engraving/Marking Equipment
New Hermes Rotary Engraving System
Epilog Laser Engraving, Cutting and Marking system
AXYZ 5 x 10 CNC Router with I Cut
Cincinatti Super Jet III Jet Dryer 1,000,000 BTU
Multiple UV reactor drying systems
Cutting Equipment
Thomson American Clamshell Diecutter
Prism Digital Control Powercutter
Gerber M 3000 Digital Plotter, Cutter and Router
AXYZ Router with I-Cut
Laminating Equipment
Multiple Laminators: hot and cold, 24″ up to 64″
Packaging Equipment
ZED Blister Pack Machine
Shrink Wrap and Heat Tunnel Machines
Digital Printing Solutions
Mimaki JV150-130 Wide Format Printer
Mimaki JV300-160 Wide Format Printer
Mimaki UCJV300-130 Wide Format Printer
Mimaki JFX200-2513 UV Flatbed Printer: 4′ x 8′ x 2″
Mimaki UJF3042 & 6042 UV Flatbed Printers: 18″ x 26″ x 4″
HP Indigo 5600 High Speed Digital Printer
Epson 9800 Medium Width Printer
Gerber Edge Printing & Cutting System

Finishing Operations

Materials can be overlaminated with various films such as polyester, polycarbonate, or vinyl to provide protection, appearance or effect. Pressure sensitive adhesives can be laminated to films or sheets to facilitate mounting functionality for the finished part. We can put together multiple layers of different materials to create insulators, shielding components or custom constructions for special applications. Copper and aluminum foils are examples of products we utilize for those special needs.
Slitting is done to create a back or front slit in a protective liner to provide the crack and peel effect for pressure sensitive products. Slitting is also used as a lower cost alternative to pull tabs on pressure sensitive adhesive-backed products. Power shearing and back slitting, for example, are alternatives to tooling and diecutting. Back slits on parts are also advantageous for strategic part placement where only part of the liner is removed and the part can be handled or positioned easily.
Diecutting by means of using Steel Rule Dies is an industry standard for cutting shaped parts or parts with interior cutouts, tabs, or large volume. All of our roll labels are produced using tooling, but in many cases, common die shapes or sizes can use common tools. In our sheet-fed products we utilize Clamshell type diecutters. For smaller quantities or larger products, our Gerber M3000 can be utilized to kisscut or diecut products as a digital solution instead of a steel rule die purchase.
Powercutting is the use of a guillotine power shear with a digital readout controller to semi precision cut films, thin gauge sheets and layered constructions into square or rectangular shapes. Our largest production cutter is 54″ wide, but we do special cutting up to 12′ for products such as banners and sign inserts. Shearing is our cutting process for rectangular sheet products in gauge metals.