In the aerospace business, off-the-shelf membrane switches are rare because they are rarely sufficient. They cannot withstand the rigorous conditions unique to flight, such as extreme temperature fluctuations, rapid atmospheric pressure changes, weight limitations, and extended sunlight exposure.
This means manufacturers must buy custom switches, and that means choosing a custom membrane-switch manufacturer. This isn’t a typical procurement decision, though. It is a strategic design partnership that influences every stage of a product's life cycle, from the initial prototype to long-term field service. Here’s how you go about it.
To meet exacting aerospace specifications, a manufacturer should offer deep customization in several critical areas:
Visibility in low-light environments is a priority for pilots. Solutions should include energy-efficient LEDs, fiber optics, and light guide films (LGF) to ensure bright, uniform illumination across the interface.
Designers must choose between rigid substrates like stainless steel and lightweight, flexible polyester based on weight savings and durability needs.
Aerospace interfaces must eliminate EMI, RFI, and ESD interference through the use of aluminum foil or printed conductive inks. High-performance 3M™ adhesives or mechanical backers are necessary to ensure the switch remains durable against ongoing vibration and moisture.
Integrating silicone rubber keypads can provide a waterproof, cushioned tactile experience, while technologies like Duraswitch® offer extreme longevity in the harshest environments by eliminating the mechanical grinding common in traditional switches.
When evaluating a potential aerospace partner, prioritize the following criteria to ensure project success:
Look for a manufacturer with decades of experience specifically serving the aerospace sector. They should demonstrate a deep understanding of industry-worthy factors, including UV exposure, outgassing requirements for high altitudes, and the effects of ongoing vibration on electrical contacts.
Prioritize a single-source manufacturer that offers turnkey services—including design support, material sourcing, manufacturing, and testing. A manufacturer should act as an extension of your own engineering team, helping you select the optimal substrates and adhesives for your specific flight application.
Prototyping is essential for vetting designs and testing functionality before committing to a full production run. Reliable manufacturers deliver production-grade prototypes within days, helping keep complex aerospace projects on track.
In aerospace, reliability is imperative. Ensure that the manufacturer tests switches individually, rather than relying on batch testing, to guarantee 100% functionality. Their facility should be capable of conducting life-cycle testing (millions of actuations) and environmental qualification, such as temperature and humidity cycling.
Evaluate the total cost of the project rather than just the per-unit price. This includes Non-Recurring Engineering (NRE) fees and tooling costs, which cover design reviews, artwork preparation, and circuit layouts. Understanding how pricing shifts from prototype quantities to large-scale production runs is vital for long-term budgeting.
Choosing a domestic manufacturer (such as one based in Ohio) often provides significant advantages, including faster revision cycles, easier communication, and simplified compliance compared with overseas factories.
The right manufacturer is more than just a supplier. They are a partner in the safety and success of your aerospace application. Before making a final decision, ask technical vetting questions regarding their in-house versus subcontracted work and their typical yield rates. By selecting a partner with the right certifications, technical depth, and industry experience, you ensure that your user interface will perform reliably when it matters most.
With decades of experience specifically serving the aerospace sector, The Cubbison Company has established an enduring reputation for reliability and trust. By consistently delivering products that function optimally within a no-margin-for-error environment, we provide essential standalone components and integrated solutions for complex control panels and equipment.
We serve as a strategic design partner and turnkey service provider for some of the world’s leading aerospace manufacturers, ensuring that every interface is engineered for maximum safety and precision.
Submit your specifications today to receive a comprehensive evaluation of your project’s total cost and timeline.
mail our design team to discuss specialized substrates, advanced backlighting, or EMI/RFI shielding requirements.