Have you ever wondered how tactile switches are crafted to perfection? No electronic device is truly complete without these tiny yet essential components. Since performance and durability are paramount in electronics, manufacturers like us must produce top-quality tactile switches.
So, what’s the magic formula behind high-performing tactile switches? Is it the choice of materials or perhaps the precision of the assembly machines? The answer is a resounding “all of the above.” It’s important to understand the broader picture before diving into the nitty-gritty of tactile switch manufacturing.
This blog will unfold the entire process of manufacturing tactile switches from beginning to end; This will provide readers with information about tactile switches manufacturing and processing.
at first, a customer initiates the process by placing an order. This could be for a custom-designed tactile switch or a selection from our extensive catalogue of pre-existing designs. We present a prototype design for the customer’s approval for custom orders. Once we get the green light, our sales team formalizes the order. At this stage, the customer usually provides a pre-defined deposit as a commitment to the project.
Our manufacturing department will take action as soon as the order and design are locked in. They inventory the raw materials needed for the various components of the tactile switch—housing, actuator, and contacts. Should we find ourselves short on materials, we promptly source them from our trusted suppliers to avoid any hiccups in the production timeline.
Once all the materials are accounted for, our manufacturing team revisits the checklist for a final run-through, ensuring that every stone is turned on. This is also the moment when the final draft of the design receives its ultimate seal of approval. But wait, there’s more! Our quality assurance team strictly controls raw materials. Their mission? To ensure that every material used is of the highest quality and meets our strict quality standards.
This stage is the heart of the tactile switch manufacturing process, where the rubber meets the road. Each major component—housing, actuator, and contacts—is crafted individually. A comprehensive checklist outlines the specific materials for each part, ensuring no room for error.
The team leader then lays out a timeline for the entire manufacturing process, from kickoff to finish. A detailed operational plan is also drawn up to guide the team through each phase.
Below, we delve into two popular methods used to manufacture tactile switches
● Housing
The journey begins with a pre-shaped material that undergoes a thorough cleaning. Next, the material is subjected to the injection moulding process, where it takes its final form. Excess material is removed through turning, which involves high-speed rotation and precise cutting.
Following this, a layer of conductive material, often copper, is applied to specific housing sections to ensure proper conductivity. The housing is then polished and threaded to facilitate attachment to other components.
Finally, a protective coating, such as Teflon, is applied. A baking process follows this to ensure the coating adheres firmly to the housing.
● Actuator
The actuator follows a similar path to the housing but includes an additional material layer to provide tactile feedback. This could be a rubber or silicone layer, ensuring a snug fit and optimal performance.
● Contacts
Contacts require minimal manufacturing steps. The focus here is on cutting them to the exact dimensions specified in the design.
● Cutting and Shaping
Once the material is selected, it’s cut into the required dimensions. The next step involves partial heating to forge the metal into the desired shape.
● Trimming
Excess material, or burrs, are then removed to refine the shape further. This is followed by a flashing process to mould it into the final form.
● Sandblasting
The components are sandblasted to achieve a smooth and clean finish. Customer requirements or industry standards often dictate the granularity of the sand used.
● Machining
Further refinements are made through machining, which includes threading, hole-drilling, and other modifications based on the customer’s specifications.
● Surface Treatment
Finally, the components undergo a chemical surface treatment to enhance durability and performance.
At this stage, our skilled engineers put together all the tactile switch components harmoniously. Often, this assembly is a hands-on affair that requires a human touch to gain additional skills. At this point, each switch is assigned a unique production number. In addition, these switches are specified according to the industry standards they adhere to, be it ISO, RoHS or any other relevant certification.
In this critical phase, each tactile switch undergoes strict performance testing to detect any electrical or mechanical issues. For instance, we might subject the switches to varying voltage levels for a set duration, ranging from a couple of hours to an entire day, depending on the switch type.
Should any switch fail the test, it’s back to the repair bench for a thorough diagnosis and rework. If the switch passes with flying colours, it’s on to the final stage.
In some cases, we also use mechanical stress testing to ensure that the switch can withstand repetitive actuation. If a switch fails this test, it is sent back for rework and retesting.
Finally, our quality assurance team takes centre stage once again. They conduct a meticulous final inspection to check for any lingering issues, be it electrical faults or mechanical inconsistencies. Rest assured. Every switch leaves our factory after passing this ultimate quality checkpoint.
And there you have it—the complete journey of a tactile switch from raw materials to a high-quality, reliable component. I am intrigued to see how it’s all done. Stay tuned for our upcoming video that takes you behind the scenes of tactile switch manufacturing
Manufacturing tactile switches is far from a walk in the park—it’s a complex ballet of engineering, quality control, and meticulous attention to detail. From raw material sourcing to intricate assembly and strict testing, each step is important to the final product’s performance and reliability.
So, what sets a high-quality tactile switch apart from the rest? One key indicator is longevity. A switch that stands the test of time is a testament to its superior quality. On the flip side, if a switch experiences early failure or inconsistent performance, it’s a red flag that the manufacturing process may not be up to snuff.
In tactile switches, quality isn’t just a buzzword; it’s a promise. While top-tier switches can last for years, subpar ones might give out much sooner, sometimes in as little as a year or two.
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