CNC Laser Cut & Etched Polycarbonate Overlay with Dead-Front Graphics for the Aerospace Industry

A customer in the aerospace industry was in need of a custom front panel overlay, which was to be used in an aircraft display application. This product features dead-front graphics; which are graphics that only appear when illuminated. The paint system used allows for flexibility without cracking and was applied to meet customer specifications for light transmittance.

Manufacturing of this item required the use of a various precision fabrication capabilities, the overlay and PSA backing were laser cut on our CNC CO2 laser, with spray paint applied in our spray booth with a fine-detail spray gun. The overlay was also fiber laser etched on our Ytterbium fiber laser, the finished overlay was also oven baked and cured, then assembled.

Through the manufacturing process, the panel was subject to stringent quality control measures. Prime Products produced over 10,000 of this item for an aerospace customer in Kansas.

For more information on the complex fabrication processes and materials used on this product, see the table below or contact us directly.

CNC Laser Cutting & Etching Project Highlights

Product Name Front Panel Overlay
Product Description This Front Panel Overlay is used on an aircraft display panel.
Capabilities Applied/Processes
CNC Laser Cutting
Spray Painting
CNC Fiber Laser Etching
Screen Printing
PSA Assembly
Plasma Treating
Touch Up
Equipment Used to Manufacture Part
CNC CO2 Laser
Plasma Jet
Spray Paint Booth with Fine-Detail Spray
Ytterbium Fiber Laser
Screen Print Workstation
Batch Oven
Overall Part Dimensions 3.709" Long x 0.877" Wide x 0.020" Thick
Tightest Tolerances ±0.005"
Material Used
Lexan 8010 Clear Polish/Polish .020"
Black Epoxy Nazdar ADE52
Proprietary Dead-Front paint system
White Epoxy Nazdar ADE751K
Clear Matte Polyurethane Mix
3M 9690B Sheet (Liner Added)
Material Finish
Front Surface Matte Dead-Front
Rear Surface Polished
Nomenclature Light Transmittance 15-22%
Graphics Light Transmittance 7-13%
Opaque Black per FED-STD-595 Color #37038
Translucent White per FED-STD-595 Color #37875
In process testing/inspection performed
Dimensional Inspection
CMM Inspection
Photometer Light Transmission
Visual Inspection
Final Inspection
Industry for Use Aerospace
Volume 250 per year
Delivery/Turnaround Time 7 Weeks
Delivery Location Olathe, Kansas
Standards Met
PDF Drawing Specifications
Material Specifications
Light Transmission Specifications
FED-STD-595 Color Specifications
2D CAD Artwork
Certificate of Compliance
AS9102 First Article Inspection Report