When it comes to manufacturing high-quality silicone keypads, the difference between success and frustration often lies in one critical phase: Design for Manufacturability (DFM). At Flykeyboard, we understand the value of proactive collaboration during the early stages of product development. While we don’t provide full-scale design services or create CAD files, we regularly assist our customers by reviewing designs and offering expert feedback—ensuring smoother production, lower costs, and better end results.
If you’re working on a new silicone keypad design or refining an existing one, this guide is for you. Below, we highlight five of the most common DFM mistakes we encounter and how you can avoid them to streamline manufacturing and improve overall product quality.
1. Inconsistent Wall Thickness
One of the most frequent issues we see in silicone keypad designs is inconsistent wall thickness. While it may seem like a minor detail, even small variations in wall thickness can lead to serious complications during molding. Thick sections take longer to cure, while thinner areas may cure too quickly, causing warpage, air entrapment, or voids. Additionally, uneven curing can negatively impact the tactile feel and the keypad’s long-term durability.
Our Recommendation:
Maintain uniform wall thickness wherever possible, ideally between 0.040″ and 0.090″, depending on the silicone material and application. Not only does this support consistent flow and curing during the molding process, but it also reduces cosmetic defects and improves dimensional stability. If variations are necessary, aim for gradual transitions to avoid abrupt changes in material volume.
2. Unnecessary Undercuts
Undercuts are recessed or protruding features in the design that prevent easy part ejection from the mold. While undercuts may sometimes be unavoidable, they often lead to significantly more complex tooling, which drives up both mold cost and maintenance. In many cases, we’ve found that these features can be redesigned without compromising functionality.
Our Recommendation:
Evaluate whether each undercut is essential. Can the design be split into two simpler components? Could a snap-fit or adhesive join replace a mechanical interlock? Collaborating with your molding partner—especially early in the development cycle—can help uncover opportunities to simplify geometry and reduce mold complexity.
3. Overly Complicated Key Shapes and Legends
Keypad aesthetics matter—but overly detailed key shapes, sharp corners, and intricate legends often introduce more problems than they solve. Fine features may not mold cleanly or could wear quickly under repeated actuation. Inconsistent filling during molding can also lead to incomplete characters or inconsistent texture.
Our Recommendation:
Keep key profiles as clean and smooth as possible. For legends and symbols, use bold, clearly defined elements with enough stroke width to ensure reliable molding and printing. At Flykeyboard, we can advise on minimum font sizes and depth tolerances to ensure optimal results for both screen printing and laser etching processes.
4. Inadequate Light Management for Backlit Keypads
If your product involves backlighting, special attention must be given to material selection, layout, and light-blocking features. One of the biggest mistakes designers make is assuming the light will stay where it belongs. Without proper planning, light often leaks into unintended areas, creating a distracting or unprofessional appearance.
Our Recommendation:
Integrate light-blocking barriers and select materials with suitable transmission or diffusion properties early in the design phase. At Flykeyboard, we offer custom insert molding solutions, opaque barriers, and localized diffusion options to ensure crisp, isolated illumination only where it’s needed. Whether you’re using EL film, LEDs, or fiber optics, we’ll help you plan for clean and effective backlighting.
5. Ignoring Assembly Fit and Tolerances
Silicone is flexible, which gives it some design forgiveness—but this shouldn’t lead to complacency when it comes to fit and tolerances. A poorly fitted keypad can result in sealing failures, misalignment with circuit boards, or inconsistent tactile feedback. Overlooking these considerations during design often results in rework, added production time, or suboptimal user experience.
Our Recommendation:
Provide complete assembly drawings and define all relevant mating components. Pay special attention to features such as key height, edge frames, adhesive interfaces, and sealing zones. At Flykeyboard, we’ll review these aspects carefully and suggest enhancements like support frames, retention ribs, or custom backings to ensure secure and accurate installation.
Let’s Design It Right—Together
At Flykeyboard, we take pride in offering more than just manufacturing—we deliver partnership. Our engineering team is committed to helping you build better silicone keypads by providing insightful, no-cost design feedback before tooling begins. Whether you’re launching a new product or improving an existing one, getting DFM right from the start can save time, money, and a lot of stress.
We invite you to share your drawings and requirements early in your project timeline. While we don’t offer full design services or CAD development, our experienced team is here to guide you through the manufacturability review process—so your keypad performs as beautifully as it looks.