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Overlays and Artwork Files Frequently Asked Questions

What artwork do your require?

We are an all-digital print manufacturer so that we can save you time and money if you provide us with the correct artwork for your graphics. This requires that you follow a few simple rules:

• Please check your graphic design for layout, color, and spelling.
• Please insure that your graphic overlay will align properly over the aluminum plate.
• Please specify any window or clear areas on your design.
• Please insure that you upload all files for your graphic overlays, along with the design files for any aluminum panels, when you place your order.
• Please convert all text to outlines.

What material do you make the graphic overlays from?

Our graphic overlays are manufactured from a printable vinyl substrate. We then apply a scratch resistant laminate to the vinyl that gives the overlay the look, feel, and durability of silk-screened Lexan, though not as thick. Our graphics overlays are 5-7 mil thick; we have found this to be effecting in covering most common holes and other depressions in the panel without leaving a dimple or other visible mark on the overlay.

How durable is the graphic overlays?

The graphics label material is very durable and in normal use will not scratch, crack, discolor or fade.

How is the graphics overlay applied to the faceplate?

If you purchase a panel with a matching overlay we will install the overlay for you and ship it as a complete unit. If you need to apply the overlay yourself the process is relatively simple.

The graphics overlay is adhesive backed, remove the overlay from protective backing material. Spray the panel and the overlay with a mixture of soap and water: this allows the overlay to easily slide over the panel and makes it easier to align and adjust it with the panel. The soap and water does not affect the adhesive, and when the water evaporates the adhesive will fully set and the overlay will be firmly in place. After aligning the overlay and the panel squeeze the water from between the overlay and the panel using a squeegee, credit card, or other flat, smooth, scratch less tool. Squeegee the water from the center of the panel out towards the sides to force the soapy water solution out from underneath the overlay. Keep squeezing the water until the overlay is completely flat, and without any air or water bubbles, then dry-off the panel with a paper towel. Inspect the panel again to insure a clean and accurate fit. If you would like to re-adjust the overlay you can carefully pull it off the panel and try again. As long as you keep the overlay wet you can keep reapplying it, but to avoid stretching or deforming the overlay by repeatedly lifting it you should not lift if off the panel more then a few times.

For a short demonstration of the above technique please review this short overlay installation video.

What colors are available?

We can manufacture your label from any color CMYK color. The one color that we can not print is white. We create white text and graphics (like on a common black background with white text panel), by reverse printing. The backing material is white, and we print the other colors around it leaving the white background visible where necessary.

What are the available shapes for the graphics overlays ?

Graphic labels can be any shape, but in most cases we find customers are using them to cover rectangular faceplates like those used on extruded aluminum enclosures. The outside shape of your label is cut by our automated cutting system directly from the outlines you indicate in your graphics file, or we can cut it to match your faceplates.

How to we specify cut-out shapes for connectors, switches, buttons, LED's etc?

Please draw the shape of any cuts you require on your graphic overlay to align with the cutouts in your faceplate. Over sizing your label cutout by .025 to .05 inches larger then the matching faceplate cut out (like in the case of a connector) simplifies the installing of the cutouts.

What graphics format do you require?

We prefer graphic files in Illustrator CS3 or lower or Corel 8 or lower. These two programs are vector based and provide the best results when logos, graphics, and text is scaled, aligned, and manipulated to fit cleanly onto your panel artwork. We can also provide great results with any program that outputs "eps" file formats.

Do you accept bitmap file formats like jpg, tiff, and png?

While not providing the same high accuracy as the Illustrator or Corel vector file formats, we can also process bitmap files created by popular programs like Photoshop. Please provide these files with a a resolution of 300 dpi or more.

How do we send you our files?

You can upload your artwork files when from the online shopping cart . If you are ordering more then one panel please separate all overlay artwork into separate files and upload them along with your order. If you would like to send notes, pictures, or documents to help us produce your overlays lease place all of these files into a zip file and upload one zip file for each item in your order - this helps us maintain our fast delivery service. If you have any questions ... just give us a call.

How do I specify transparent/translucent colors, say for windows that are lighted by LEDs?

Please show translucent areas as white.

What is the best way to make a round or rectangular LED window or lens?

The best way to make an LED window or lens is by specifying a translucent circle or rectangle on the overly in front of the LED. We have experimented with printing colored LED windows but have concluded that the best results, in the widest range of applications is to provide a translucent window and allow the color of the LED to illuminate it. The LED window/lens will have a slight matte or textured appearance to it when illuminated caused by the overlay material and also the adhesive on the back of the overlay.

What type of LED's produce the best results?

Super bright LED's, or LED's with 25mcd or more work the best, and red seems to provide the best contrast in all lighting conditions. Size does not matter.

If I need translucent windows or lenses for my LED's, can you avoid placing adhesive in those areas of the overlay?

The laminate used on our overlays comes totally covered in adhesive and there is not way to selectively apply or remove the adhesive. Typically LED's are recessed behind the overlay into the matching panel hole, and the LED does not touch the overlay so there are no problems with the LED's sticking to the overlay and damaging it when removing the circuit board or LED. A 0.025 inch gap between the LED and overlay provides good illumination results.

What can I do to eliminate light bleeding from one LED to an adjacent one?

Typically, if you design your panel so that the tip of your LED pokes into a matching hole on the panel this isn't a concern. Most LED's are directional and emit light from the front so that fact, and the fact that adjacent LED's are covering their holes with their own bodies eliminates light bleeding.

Can you design my graphics overlay?

We cannot design your graphic overlay from the concept stage, however we can help you compose and finalize your design. Please send us your rough design including all graphic elements, text and CAD files for your aluminum panel. Our graphics technician will then prepare a draft overlay artwork for your approval.

Other considerations about your graphics overlay

We use a commercial grade all-digital printer, so the image mode and resolution of your artwork are extremely important to ensure correct color and clarity. All jpg and tiff files need to have a resolution of 300 dpi. at actual size. Our equipment is currently set to print CMYK modes only and all RGB images will be converted, which can cause extreme shifts in color.  If your unsure of any these details and how it relates to your label you don't need to worry since we will be sending your a proof of your label and will give you the opportunity to provide us with any feedback or changes. The proof is sent within a day or two of receiving your online order, and we only ask that you respond promptly (within 6 hours) since we can only delay a job if we have notice that it may need changes.

Can we print spot PMS colors?

Not currently.  Our digital equipment uses a four color CMYK process .  While we cannot print an actual PMS spot color, we can print a very close approximation to the color.