Manufacturing Processes
Every part we ship is built entirely in our own facilities — from raw film and ink to finished, tested assembly. Five core processes give us full control over quality, cost, and lead time.
In-House Capabilities
How We Build Your Parts
All five processes are performed in our Monterrey facility, with finished goods warehoused in Houston for fast US delivery.
Screen Printing
High-precision ink application for graphic overlays and membrane switches.
Screen printing is a stenciling technique used to apply inked images to a wide variety of substrates. Using a stencil, or a series of stencils, ink is distributed onto the desired area by being pressed through a porous screen. Our semi-automatic and high-speed screen printing machines provide excellent performance on final products such as graphic overlays and membrane switches. We have the capability to Pantone-match colors to meet exact customer requirements.
- Pantone color matching
- Semi-automatic & high-speed presses
- Suitable for polycarbonate, polyester, and specialty films
- Consistent registration across multi-layer prints
Digital Printing
The ideal solution for intricate designs, photographic detail, and short runs.
Digital printing is the best option for printing intricate designs on substrate films where small visual details are critical or photos need to be reproduced as the final design. Our Mimaki digital printer provides excellent ink adhesion and accurate reproduction of digital files, offering exceptional print quality without the setup time or cost of screen printing tooling.
- Photo-quality reproduction
- No tooling cost — ideal for prototypes and short runs
- Mimaki digital inkjet printer
- Excellent adhesion on flexible substrates
Embossing
Raised tactile features for key feedback, branding, and premium aesthetics.
Embossing is used when areas of a graphic overlay or membrane switch need to be raised so users can feel the feedback of the key being pressed. It serves both aesthetic and functional purposes across industries. Ensel offers three embossing styles to match the requirements of any application.
- Polydome — rounded raised key for tactile feedback
- Rail — linear ridge for slider or multi-key groupings
- Pillow — flat raised area for indicator or display windows
- Compatible with both screen and digitally printed overlays
Die Cutting
Repeatable, cost-effective cutting for medium and large production runs.
Die cutting uses a steel rule die assembled onto custom-carved wood and attached to a press. This form of cutting offers the repeatability needed for medium and large production runs. It is the standard method for cutting membrane switch layers, graphic overlays, adhesive gaskets, and converting products where consistent shape and edge quality are required at volume.
- High repeatability for consistent part dimensions
- Low per-unit cost at medium and high volumes
- Fast cycle times for production efficiency
- Capable of complex shapes and tight tolerances
Laser Cutting
Precision cutting of any shape to critical dimensions — ideal for short runs.
Laser cutting is one of the best options for materials where critical dimensions are specified as a requirement. It allows us to cut materials of any thickness into any shape without compromising quality, and provides the precision needed for prototype work, complex geometries, or parts with very tight tolerances. It is ideal for short runs where tooling cost must be avoided.
- No tooling required — cut from digital file directly
- Precision cuts to ±0.1mm or better
- Handles complex shapes and cutouts
- Ideal for prototypes and low-volume parts
Quick Reference
Full Capabilities at a Glance
| Process | Details |
|---|---|
| Screen Printing | Semi-auto & high-speed presses, Pantone matching |
| Digital Printing | Mimaki inkjet, photo-quality reproduction |
| Embossing | Polydome, rail, and pillow emboss tooling |
| Die Cutting | Steel rule dies, custom shapes, high volume |
| Laser Cutting | Precision cuts, no tooling, any geometry |
| Lamination | Automated adhesive lamination, 3M materials |
| Electrical Testing | 100% in-house continuity and actuation testing |
| Assembly | Clean-room assembly, stiffener and connector attachment |
Quality Commitment
ISO 9001:2015 — Every Step of the Way
Ensel is committed to continuous improvement and quality. We follow international quality standards — including ISO 9001:2015 — to ensure the highest level of service at every stage of production.
We welcome customer audits whenever necessary throughout the year to reassure the performance and reliability of every part we manufacture and ship to our valued customers.
100%
In-House Testing
ISO 9001
2015 Certified
25+
Years Experience
5
Core Processes
See What We Make
Products Built With These Processes
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