Dead front printing

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By Debbie Anderson | Jul 07, 2020
Dead-front control panel

When developing a user interface, it’s important to consider what the user needs to see during an interaction. For certain applications, calling attention to an indicator or warning light while keeping others hidden can be crucial. For situations where eliminating distractions, keeping a clean aesthetic, and emphasizing certain switches or indicators is imperative, look no further than dead front printing.

What is dead front printing? 

Dead front printing is the process of printing alternate colors behind the main color of a bezel or overlay. This allows indicator lights and switches to be effectively invisible unless actively being backlit. Backlighting can then be applied selectively, illuminating specific icons and indicators. Unused icons stay hidden in the background, calling attention solely to the indicator in use.

Printing methods and substrates for dead front overlays 

There are two ways to illuminate a dead front overlay, each of which requires a different printing approach. The first method is to use LEDs directly behind each indicator or icon. This approach simplifies the printing process (since LEDs provide the colors, the printing generally employs a single color behind each button). Alternatively, different translucent colors can be printed selectively behind various indicators. With the use of translucent colors, almost any backlighting method can be used since it’s the ink behind the iconography that gives the indicator its hue.

Diffusers are often applied behind the lights to maintain consistency throughout an overlay. Particularly with LEDs, diffusers can help eliminate hotspots, where one part of the letter or icon appears much brighter than other parts. Once a part is ready, a standard is made, so any future overlays or alterations are readily available and can easily be matched to the standard.

While dead front printing is technically possible with almost any colored bezel or overlay, it’s generally seen on overlays and bezels printed with neutral colors. Typically printed on polycarbonate, polyester, or glass, colors such as white, black, or gray tend to hide unused indicators the most effectively. 

Developing dead front control panels with GMN

When developing a new dead front overlay, experimentation is often necessary to get the perfect look. Given the breadth of possible lighting options, ink densities, color palates, and substrates, maintaining a consistent look across an overlay often requires several prototypes to be developed. At GMN, we have a state-of-the-art color lab, a light lab, and a full printing team that works in tandem to match and perfect colors. Within our color lab, spectrophotometers and spectroradiometers are frequently utilized to get specific color values necessary for matching. Our light lab will then work with the printing team to narrow down the exact mixture and density of ink necessary for the specific substrate and required look.

Dead front printing is an excellent option for a wide variety of applications such as automotive dashboards, aerospace indicators, and touch user interfaces. Want to learn how dead front printing can help your product be more efficient while ensuring a clean aesthetic? Schedule a consultation with our experts.