In flexible electronics, flexible membrane switches consist of a flexible substrate that houses all the functional components, and a graphic overlay that interacts directly with users. Together, they allow for the customization of control panels, meeting both aesthetic and functional requirements.
Common substrates like polyethylene terephthalate (PET) are particularly effective in human machine interface (HMI) applications, including dishwashers, washing machines, hospital beds, and treadmills. Recent advances in material science have introduced more eco-friendly materials, leading us towards a more sustainable future.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/webflow/6334888a34bfac03b46aa715/660eb98c74994e52e272f5b6_Flexible%20Membrane%20Keyboard%20with%20Conductive%20Silver%20Ink%20and%20Dielectric%20Ink%20on%20PET.webp)
![applications](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/materials.webp)
APPLICABLE INDUSTRIES
- Consumer electronics
- Medical equipment
- Home appliances
- Automotive
- Aerospace
COMMON SUBSTRATES
- Silver-based inks
- Copper-based inks
- Carbon-based inks
- Dielectric inks
COMMON MATERIALS
- Biaxially oriented polyethylene terephthalate (BOPET)
- Polycarbonate (PC)
Current landscape
It is projected that the market size for membrane switches will double, reaching approximately $12.36 billion US by 2032, with Europe expected to experience the biggest expansion. As the market expands, there is a growing need for more sustainable solutions across various industries, including medical equipment, energy management systems, and consumer electronics.
Despite the promising outlook, there are currently several underlying challenges to using flexible membrane switches en masse in printed electronics.
Membrane switch market size 2022 to 2023 (USD billion)
![Membrane switch market graph](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/membrane_market_graph_revised.webp)
![Membranes](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/durability.webp)
Compared to rigid PCB switches, the durability of flexible membrane switches is perceived more cautiously. This is because the switches are subjected to repetitive pressure, may be cleaned with chemical agents, and can be exposed to varying conditions including high temperature, high moisture, and sunlight. Without chemical and thermal resistance, they may lose functionality over time.
Therefore, the layers need to exhibit high stability, durability, and barrier properties. For instance, PET, a common plastic material used in flexible membrane switches as a substrate and for graphic overlay, often exhibits poor mechanical stability. To achieve high tensile strength and thermal stability, it needs to undergo biaxial orientation where it is stretched in both directions in a heated environment.
![Membranes](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/costs.webp)
Costs of flexible membrane switches primarily depend on the design complexity and manufacturing process. Incorporating more features, such as tactile domes, backlighting, and additional protective coatings can increase the price. Customization tailored to specific use cases further influences the final cost.
Screen printing, a common method for producing flexible membrane switches, can cause manufacturing costs to rise rapidly. It requires a dedicated screen for the conductive layer, plus an additional screen for each color in the graphic overlay. Cost can grow higher with further customization, such as varying substrate thickness.
Challenges in scaling production notwithstanding, using flexible membrane switches are beneficial in a number of ways.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/print_bend.webp)
For product developers and researchers
One of the most notable advantages of using flexible membrane switches is their flexible and slim profile. With the potential to be less than 1 mm thick (Industrial Quick Search, 2024), they enable innovative designs, particularly in fields like flexible electronics, home appliances, and health care equipment, where a compact design is just as important as a highly responsive user experience.
From consumer electronics, such as ultra-thin computer keyboards that allow for customized backlighting in response to a set of keys being touched, to complex medical equipment, such as hematology analyzers that have a dedicated antimicrobial layer, flexible membrane switches allow for a smaller size, enhanced aesthetic appeal, specialized applications, and greater accessibility.
For product developers and researchers
One of the most notable advantages of using flexible membrane switches is their flexible and slim profile. With the potential to be less than 1 mm thick (Industrial Quick Search, 2024), they enable innovative designs, particularly in fields like flexible electronics, home appliances, and health care equipment, where a compact design is just as important as a highly responsive user experience.
From consumer electronics, such as ultra-thin computer keyboards that allow for customized backlighting in response to a set of keys being touched, to complex medical equipment, such as hematology analyzers that have a dedicated antimicrobial layer, flexible membrane switches allow for a smaller size, enhanced aesthetic appeal, specialized applications, and greater accessibility.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/print_bend.webp)
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/nova_keyboard.webp)
For the environment
Compared to traditional PCBs, using flexible membrane switches offers a more environmentally friendly option for printing electrical circuits, as it involves less material and consumes less energy. In the meantime, as more robust and durable materials become available, this industry will reduce electronic waste and its carbon footprint.
For the environment
Compared to traditional PCBs, using flexible membrane switches offers a more environmentally friendly option for printing electrical circuits, as it involves less material and consumes less energy. In the meantime, as more robust and durable materials become available, this industry will reduce electronic waste and its carbon footprint.
![](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_3840,q_75/voltera/images/applications/nova_keyboard.webp)
![Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_1200,q_75/webflow/6334888a34bfac03b46aa715/66460355ed4c202a15e302e4_Flexible%20Membrane%20Keyboard%20with%20Conductive%20Silver%20Ink%20and%20Dielectric%20Ink%20on%20PET.webp)
Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET
For this project, we used NOVA to print multilayer electrical circuits to make a compact and adaptable flexible membrane keyboard.
![Membranes](https://res.cloudinary.com/dw7fqss5m/image/upload/f_auto,c_limit,w_128,q_75/voltera/images/applications/brain_heart.webp)
In summary, advancements in material science are paving the way for the innovation and adoption of more customized, durable, and sustainable electronics. These developments will help democratize the use of flexible membrane switches in electronics for health, personal care, and sports purposes in the future.