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CUSTOMER CASES

Customer Cases & Application Examples

With over 20 years of experience in custom metal domes, membrane switches, FPC circuits, silicone buttons and dome sheet arrays, Shanyo has served more than 500 customers across automotive, medical, consumer electronics, industrial, communication and home appliance industries. Browse our real-world application cases to see how our precision-engineered input solutions solve complex challenges for leading brands worldwide.

500+
Global Customers		 20+
Years Experience		 IATF 16949
ISO 9001 Certified		 Qingdao
China Manufacturing
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Classic Cooperation Case

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Shanyo customer success story - precision metal dome solution
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Cases by Industry

Explore our application cases across six major industries. Each case demonstrates how Shanyo's custom input solutions address specific industry requirements and challenges.

Automotive electronics

Automotive Electronics

Center consoles, steering wheel controls, instrument panels, HVAC controls and automotive keypads requiring IATF 16949 compliance and PPAP documentation.

2 Cases →
Medical and healthcare

Medical & Healthcare

Patient monitors, diagnostic devices, infusion pumps, portable meters and medical keypads requiring ISO 13485, biocompatibility and sterilization resistance.

2 Cases →
Consumer electronics

Consumer Electronics

Game controllers, smart remotes, wearable devices, audio equipment and consumer keypads requiring RGB backlighting, rapid response and ergonomic design.

2 Cases →
Industrial automation

Industrial & Automation

Control panels, HMI interfaces, handheld instruments, industrial keypads and waterproof membrane switches requiring IP67 waterproofing and wide temperature range.

2 Cases →
Communication and IoT

Communication & IoT

Two-way radios, walkie-talkies, IoT sensors, smart home devices and communication keypads requiring compact design, low power and reliable switching.

2 Cases →
Home appliances

Home Appliances

Microwaves, washing machines, coffee makers, air purifiers and appliance control panels requiring food-grade silicone, heat resistance and chemical durability.

2 Cases →

Featured Case Studies

Detailed application cases showcasing how Shanyo's custom metal domes, membrane switches, FPC circuits and silicone buttons solve real-world challenges for our customers.

EV center console case
AUTOMOTIVE DOME SHEET ARRAY

Electric Vehicle Center Console Metal Dome Array

Challenge: A global Top 3 automotive Tier 1 supplier needed a custom dome array for an EV center console with 24 buttons, requiring IATF 16949 compliance, -40°C to +85°C operation, and zero defect rate over 5 million actuations per key.

Solution: Shanyo designed a custom 24-key dome array using gold-plated stainless steel domes on a polyimide substrate, with integrated adhesive gasket for IP65 sealing. We provided full PPAP Level 3 documentation including PFMEA, control plans and IMDS submission.

Results: Actuation force consistency ±8% across all 24 keys, life test passed 5 million cycles with no failure, PPAP approved on first submission. Annual volume: 300,000+ units.
Steering wheel buttons case
AUTOMOTIVE SILICONE BUTTON + METAL DOME

Automotive Steering Wheel Multifunction Silicone Keypad

Challenge: A European automaker required a 12-button silicone keypad for steering wheel controls with ergonomic curved design, sweat/UV resistance, and tactile feedback distinguishable by touch without visual confirmation.

Solution: Shanyo developed a custom silicone keypad using UV-resistant silicone with laser-etched legends, integrated with four-leg metal domes for high tactile ratio (55%). The curved 3D keypad was overmolded onto a flexible PCB for ergonomic fit.

Results: Tactile ratio 55% with consistent click sound 45dB, passed 1000 hours UV exposure and sweat resistance testing. Blind tactile differentiation achieved through varying key heights and textures. Annual volume: 500,000+ units.
Medical monitor membrane switch case
MEDICAL MEMBRANE SWITCH

Medical Patient Monitor Membrane Switch Keypad

Challenge: A medical device manufacturer needed a 30-key membrane switch for a patient monitor requiring ISO 13485 quality system, biocompatible materials, disinfectant resistance (hospital-grade cleaners), and LED backlighting for all keys.

Solution: Shanyo manufactured a custom membrane switch using medical-grade polyester with UV-cured ink, integrated LED light guide film for uniform backlighting, and a sealed polyester overlay resistant to isopropyl alcohol, bleach and quaternary ammonium disinfectants.

Results: Passed 500+ disinfectant wipe cycles with no legend degradation, LED brightness uniformity ±12% across all 30 keys, ISO 10993 biocompatibility certified. Supported customer's FDA 510(k) submission with full documentation.
Blood glucose meter FPC case
MEDICAL FPC + METAL DOME

Portable Blood Glucose Meter FPC Keypad Module

Challenge: A medical diagnostics company required an ultra-thin (0.3mm total thickness) FPC keypad module with 4 metal dome buttons for a portable glucose meter, needing bendable circuit for compact enclosure and low-voltage reliable switching.

Solution: Shanyo designed a 0.025mm polyimide FPC with 4 integrated gold-plated metal domes (5mm diameter), ENIG surface finish for low contact resistance, and a stiffener frame for dome support. The FPC included test strip contact pads and display connector.

Results: Total module thickness 0.28mm, contact resistance ≤30mΩ at 1.5V/1mA, passed 1 million actuation life test. FPC bend test passed 10,000 cycles at 5mm radius. Annual volume: 1,000,000+ units.
Game controller D-pad case
CONSUMER ELECTRONICS METAL DOME ARRAY

Game Controller D-Pad Metal Dome Array Solution

Challenge: A leading gaming peripheral brand needed a custom D-pad dome array for a pro controller requiring 8-way directional input, rapid response time (<1ms), high tactile feedback, and 10 million actuation life for competitive gaming.

Solution: Shanyo developed a custom 4-dome cross array using high-cycle beryllium copper domes with multi-tactile design for 8-way input. The dome array was assembled on a polyester substrate with precision-aligned adhesive, achieving 60% tactile ratio and sub-millisecond response.

Results: Response time 0.8ms, tactile ratio 60%, life test passed 10 million cycles with no force degradation. D-pad 8-way input verified with no ghosting. Customer reported 30% improvement in player input accuracy in competitive testing.
Smart remote RGB case
CONSUMER ELECTRONICS SILICONE KEY + LED

Smart Remote Control Silicone Keypad with RGB Backlighting

Challenge: A smart home brand required a 20-key silicone keypad for a premium remote control with per-key RGB addressable backlighting, translucent silicone for uniform light diffusion, and low-profile design for ergonomic one-handed use.

Solution: Shanyo manufactured a custom silicone keypad using translucent medical-grade silicone with laser-etched legends, integrated with WS2812 addressable RGB LEDs on a flexible PCB. A custom light guide film ensured ±15% brightness uniformity across all keys.

Results: Per-key RGB lighting with 16 million colors, brightness uniformity ±12%, keypad total thickness 1.2mm. Passed 3 million actuation life test. The remote won a 2025 Red Dot Design Award for user interface design.
Industrial control panel case
INDUSTRIAL WATERPROOF MEMBRANE SWITCH

Industrial Control Panel Waterproof Membrane Switch

Challenge: An industrial automation manufacturer needed a 40-key membrane switch for a factory HMI panel requiring IP67 waterproofing, -40°C to +85°C operation, resistance to cutting fluids and oils, and emergency stop button with tactile distinction.

Solution: Shanyo designed a fully sealed membrane switch with polyester overlay, acrylic adhesive gasket, and integrated metal domes. The emergency stop used a red high-tactile dome (65% ratio) for blind identification. All materials selected for oil and chemical resistance.

Results: IP67 verified by 1-meter water immersion for 30 minutes, passed 1000 hours salt spray and 500 hours cutting fluid exposure. Temperature cycling passed 1000 cycles. Installed in over 200 factory production lines worldwide.
Handheld measuring instrument case
INDUSTRIAL METAL DOME

Handheld Digital Measuring Instrument Metal Dome Keypad

Challenge: A precision instrument manufacturer required a 6-button metal dome keypad for a handheld coating thickness gauge, needing glove-operable keys (large target area), drop shock resistance, and consistent force for field use in construction environments.

Solution: Shanyo selected 10mm four-leg metal domes with 200g actuation force for glove-friendly operation, mounted on a rigid FR-4 PCB with shock-absorbing silicone overlay. Keys designed with 12mm target area and raised tactile rims.

Results: Passed 1.5-meter drop test onto concrete 20 times with no dome damage, glove operation verified with standard work gloves, force consistency ±10% after 500,000 actuations. Used by inspection professionals in over 30 countries.
Walkie-talkie dome array case
COMMUNICATION DOME SHEET ARRAY

Professional Two-Way Radio Dome Array Keypad Module

Challenge: A communication equipment manufacturer needed a 16-key dome array for a professional walkie-talkie requiring compact design (keypad area 40×60mm), dust/water resistance for outdoor use, and low-voltage switching for battery-powered operation.

Solution: Shanyo designed a high-density 16-key dome array using 5mm round domes on a 0.05mm polyester substrate, with 2.5mm key pitch. Nickel-plated domes for solderability, integrated dust seal overlay, and custom FPC tail for main board connection.

Results: Keypad module total thickness 0.45mm, contact resistance ≤50mΩ at 3V/1mA, IP54 dust/water protection. Passed 2 million actuation life test. Operating temperature -30°C to +70°C for outdoor field use.
IoT FPC antenna case
COMMUNICATION / IOT FPC

IoT Smart Sensor FPC Antenna + Button Integration

Challenge: An IoT startup required an integrated FPC solution combining a 2.4GHz antenna, 2 metal dome buttons, and sensor connector on a single flexible circuit for a battery-powered smart home sensor, needing ultra-compact size and low power consumption.

Solution: Shanyo designed a single-piece polyimide FPC (0.1mm) integrating a printed 2.4GHz inverted-F antenna, 2 gold-plated metal domes (6mm), and a 6-pin FPC connector for sensor module. PI coverlay for insulation, with stiffener at button area.

Results: Antenna gain 2.1dBi with VSWR <1.5 across 2.4-2.5GHz, button contact resistance ≤30mΩ, total FPC size 25×35mm. Battery life extended 20% due to low-loss antenna design. Deployed in 50,000+ smart home sensors.
Microwave control panel case
HOME APPLIANCES SILICONE KEY ARRAY

Microwave Oven Control Panel Silicone Keypad Array

Challenge: A major appliance brand needed a 20-key silicone keypad for a microwave oven control panel requiring heat resistance (up to 85°C ambient), food-grade silicone, grease/food spill resistance, and numeric keypad with tactile feedback for blind operation.

Solution: Shanyo manufactured a custom silicone keypad using FDA food-grade high-temperature silicone, with integrated round metal domes (8mm) for numeric keys and four-leg domes for function keys. Laser-etched legends with LED backlighting, sealed design for spill protection.

Results: Passed 85°C/85% RH 1000-hour test, food contact compliance FDA 21 CFR 177.2600, grease resistance verified with vegetable oil 500 hours. Numeric keypad tactile accuracy 99.5% in blind testing. Annual volume: 800,000+ units.
Washing machine membrane switch case
HOME APPLIANCES MEMBRANE SWITCH + DOME

Washing Machine Membrane Switch with Metal Dome Buttons

Challenge: A European appliance manufacturer required a 12-button membrane switch for a front-loading washing machine control panel, needing detergent/bleach resistance, humidity protection (95% RH), and a rotary encoder integration with tactile push function.

Solution: Shanyo designed a custom membrane switch with chemical-resistant polyester overlay, integrated metal domes for all 12 buttons, and a center hole for rotary encoder with push-down dome (12mm four-leg). Full acrylic adhesive sealing for humidity protection.

Results: Passed 95% RH/60°C 1000-hour test, detergent resistance verified with standard laundry detergent 500 hours, rotary push function life 500,000 cycles. Control panel passed IEC 60335-1 appliance safety standard. Annual volume: 400,000+ units.

Customer Success Stories: Precision Metal Dome Solutions

Explore detailed success stories from our flagship customers. Click each case to learn how Shanyo's precision metal dome solutions delivered measurable results.

Trusted by Leading Brands Worldwide

Our customers include Fortune 500 companies, leading automotive Tier 1 suppliers, medical device manufacturers and top consumer electronics brands across 60+ countries.

Motorola Amazon Goertek Apple
Global Auto Tier 1 Medical Device Co. Gaming Brand Smart Home Co.
Industrial Mfg. Appliance Brand Communication Co. IoT Startup

* Customer names shown with permission. Other customers under NDA.

What Our Customers Say

500+ global customers trust Shanyo for precision input solutions. Average partnership duration: 8+ years. Customer retention rate: 98%.

★★★★★

"Shanyo's metal dome arrays passed our most stringent automotive validation requirements. Their IATF 16949 quality system is robust, and PPAP documentation was approved on first submission. Over 3 years of partnership, we've received 5 million+ pieces with zero batch quality issues. Their engineering team's DFM feedback saved us 20% on tooling costs."

Procurement Director

Global Top 3 Automotive Tier 1 Supplier | 3+ years partnership
★★★★★

"Medical-grade membrane switches require exceptional biocompatibility and disinfectant resistance. Shanyo's ISO 13485 certified facility and material selection expertise helped our patient monitor panel pass FDA 510(k) certification. Their technical team responds within 24 hours, and their prototype turnaround of 10 days accelerated our product launch by 6 weeks."

R&D Manager

Medical Device Manufacturer | 5+ years partnership
★★★★★

"From game controller D-pad metal domes to smart remote silicone keypads with RGB backlighting, Shanyo provides a true one-stop solution. Their in-house tooling capability reduced our new product development cycle by 40%. The RGB backlight design they proposed was creative and professional, and our remote won a Red Dot Design Award. Highly recommended for consumer electronics brands."

Product Design Lead

Leading Consumer Electronics Brand | 4+ years partnership
★★★★★

"Our industrial control panels operate in extreme environments from -40°C Siberian winters to +85°C factory heat. Shanyo's waterproof membrane switches passed 1000 hours of salt spray and temperature cycling testing. Their flexible MOQ policy and small-batch prototyping support made it easy to validate designs before mass production. Quality is consistently excellent."

Engineering Manager

Industrial Automation Company | 6+ years partnership

Manufacturing Capabilities & Quality Assurance

Production Capacity

  • Metal domes: 50 million+ pieces/month
  • Membrane switches: 1 million+ pieces/month
  • FPC circuits: 2 million+ pieces/month
  • Silicone keypads: 3 million+ pieces/month
  • Dome sheet arrays: 2 million+ pieces/month
  • Factory area: 8,000+ sqm (Qingdao)
  • Employees: 200+ (30+ engineers)

Quality Certifications

  • ISO 9001:2015 - Quality Management
  • IATF 16949:2016 - Automotive Quality
  • ISO 13485:2016 - Medical Devices
  • ISO 14001 - Environmental Management
  • ISO 45001 - Occupational Health & Safety
  • UL 94V-0 - Flame Retardant Materials
  • RoHS / REACH / Halogen-Free Compliance

Key Equipment

  • High-speed precision stamping presses (300 spm)
  • Silicone liquid injection molding (LIM) machines
  • Automatic screen printing lines (UV curing)
  • Laser cutting and laser etching machines
  • Automatic dome array lamination machines
  • AOI automatic optical inspection systems
  • Force/displacement testing machines (±5g)
  • Life cycle testing machines (24/7 operation)

Quality Control Process

  • IQC - 100% incoming material inspection
  • IPQC - In-process inspection every 2 hours
  • FQC - 100% final electrical & visual test
  • OQC - AQL 0.65 outgoing quality audit
  • 100% force sorting (±10% tolerance)
  • 100% continuity & insulation testing
  • SPC statistical process control
  • COA with every shipment

Engineering & Innovation Capabilities

20+ years of precision engineering expertise. 100% in-house tooling. 15+ utility model patents. Annual R&D investment: 5%+ of revenue.

Precision stamping

Precision Stamping Technology

High-speed presses at 300 spm, dome dimensional accuracy ±0.02mm, force tolerance ±10%. Self-developed multi-station progressive dies with up to 32 stations. Supports 0.05mm ultra-thin material stamping.
Membrane switch printing

Membrane Switch Process

Screen printing accuracy ±0.05mm, UV-cured inks, laser-cut outlines. Supports LED/EL/RGB backlight integration with ±15% uniformity. IP67 waterproof rating, 5 million+ key life.
FPC manufacturing

FPC Manufacturing

Polyimide substrate 0.025-0.1mm, line width/spacing 0.075mm, 1-4 layer boards. Supports SMT assembly, stiffener reinforcement, shielding film. Bend test: 100,000+ cycles without breakage.
Silicone molding

Silicone Molding Technology

Liquid injection molding (LIM) + compression molding, key dimensional accuracy ±0.05mm. Supports conductive, food-grade, high-temp silicone. Laser etching depth 0.03-0.1mm with uniform light transmission.
Materials R&D

Materials R&D Innovation

Joint development with material suppliers: high-cycle dome material (10M+ cycles), anti-microbial silicone (silver ion), sweat-resistant dome plating. 5%+ annual revenue invested in material and process R&D.
Automated inspection

Automation & Testing

AOI covers 100% product appearance. Automatic force sorting machines (±5g precision). Online resistance testing. Life test machines running 24/7. SPC statistical process control for real-time quality monitoring.

How We Work Together

A proven 6-step collaboration process from initial inquiry to mass production and ongoing support.

1

Inquiry & Requirements

24-hour response. Dedicated engineer assigned. Requirements analysis & solution proposal.
2

DFM Design Review

Free design for manufacturing review. Material & process recommendations. Cost optimization.
3

Prototype & Testing

7-15 day prototype. Full dimensional & functional test reports. Sample validation & approval.
4

Pilot Production

100-1000 piece small batch. Process validation. PPAP documentation (automotive). Quality verification.
5

Mass Production

20-35 day lead time. 100% full inspection. COA with every lot. Global shipping via DHL/FedEx/sea.
6

Ongoing Support

Dedicated account manager. 24-hour technical response. Quarterly quality reviews. Continuous improvement.

Global Delivery & After-sales Support

🌍 Global Market Coverage

  • 60+ countries and regions served
  • North America: USA, Canada, Mexico
  • Europe: Germany, UK, France, Italy, Poland, etc.
  • Asia Pacific: Japan, Korea, Southeast Asia, India
  • South America: Brazil, Argentina
  • Export ratio: 70%+ of total revenue

📦 Delivery & Logistics

  • Samples: 7-15 days, DHL/FedEx express
  • Mass production: 20-35 days
  • Rush orders: Priority scheduling, 10-day fastest
  • Packaging: Export carton + moisture bag + EPE cushion
  • Shipping: DHL/FedEx/UPS, sea/air/rail multimodal
  • Inventory: VMI consignment stock available

🛡 Quality Assurance & After-sales

  • Defect rate: ≤50ppm (100% inspection)
  • Response: 24-hour quality complaint reply
  • Resolution: 48-hour solution proposal
  • Warranty: Free replacement for quality defects
  • Technical support: Dedicated engineer + account manager
  • Continuous improvement: Quarterly reviews, annual audit

📄 Compliance & Documentation

  • Automotive: PPAP Level 3, IMDS, 8D, control plans
  • Medical: ISO 13485 docs, biocompatibility, sterilization
  • General: COA, MSDS/SDS, RoHS/REACH declarations
  • Origin: Certificate of Origin (CO/Form A/E)
  • NDA: Strict confidentiality agreements
  • Traceability: Full lot traceability from raw material

Frequently Asked Questions

Q: How do I start a custom project with Shanyo?
A: Simply send us your requirements including product type (metal dome, membrane switch, FPC, silicone keypad, dome array), specifications (dimensions, force, life, temperature), quantity, and any drawings or samples. We will respond within 24 hours with a dedicated engineer assigned to your project. We offer free DFM (Design for Manufacturing) review and can provide recommendations on material selection, process optimization and cost reduction. NDA agreements are available before sharing detailed design information.
Q: What is the sample lead time and minimum order quantity (MOQ)?
A: Standard prototype lead time is 7-15 days depending on product complexity and tooling requirements. Rush prototyping (5-7 days) is available for simple designs. Standard MOQ is 10 pieces for prototyping and 1,000 pieces for mass production. However, we evaluate each program individually and can accommodate lower volumes for NPI, qualification, certification and launch phases. For standard catalog sizes and configurations, we may have inventory available with no MOQ and 1-3 day lead time. Tooling costs typically range from $300-$1,500 depending on complexity and cavity count, and may be refunded or amortized for high-volume programs.
Q: Can you provide PPAP, IMDS and other automotive industry documentation?
A: Yes. As an IATF 16949 certified manufacturer, we provide full automotive industry documentation including PPAP (Production Part Approval Process) Level 3 submission packages containing PFMEA (Process Failure Mode and Effects Analysis), control plans, process flow diagrams, dimensional reports, material certifications, performance test reports, and MSAs (Measurement System Analysis). We also support IMDS (International Material Data System) submission for material composition reporting, 8D problem-solving reports for quality issues, SPC (Statistical Process Control) data, and annual product revalidation. Our quality team has extensive experience supporting automotive OEM and Tier 1 supplier qualification processes worldwide.
Q: How do you ensure product quality and consistency across mass production?
A: We implement a comprehensive 4-stage quality control process: IQC (Incoming Quality Control) with 100% material inspection and COA review; IPQC (In-Process Quality Control) with inspections every 2 hours and SPC monitoring; FQC (Final Quality Control) with 100% electrical testing (continuity, insulation, contact resistance), 100% force sorting (±10% tolerance), and 100% visual inspection; OQC (Outgoing Quality Control) with AQL 0.65 audit before shipment. We use AOI (Automated Optical Inspection) systems for appearance, automatic force/displacement testing machines (±5g precision), and life cycle testing machines running 24/7. Every shipment includes a COA (Certificate of Analysis) with full test data. Our target defect rate is ≤50ppm, and we offer free replacement for any quality-confirmed defects.
Q: Do you offer turnkey assembly including PCB, displays and other components?
A: Yes. We provide full turnkey assembly services beyond just keypads and domes. Our capabilities include PCB/FPC design and fabrication, SMT component assembly (LEDs/RGB, resistors, capacitors, ICs, sensors, connectors), display module integration (LCD/LED/OLED), touch sensor integration, buzzer/speaker integration, connector and wiring harness integration, analog stick/hall sensor integration (for gaming), and final housing assembly. We support full turnkey (we source all components), partial turnkey (we source some, customer provides others), and consignment (customer provides all components) models. This one-stop approach reduces your supply chain complexity, shortens lead times, and ensures seamless integration between keypad, electronics and enclosure.
Q: Can you sign NDA agreements and protect our design confidentiality?
A: Absolutely. We take intellectual property protection very seriously. We are willing to sign mutual NDAs (Non-Disclosure Agreements) before receiving any sensitive design information, and we can accommodate customer-specific NDA templates. All customer drawings, CAD files, specifications and product information are stored in secure access-controlled systems with role-based permissions. Our factory has restricted access zones for prototype and custom production. We do not share customer designs with third parties, and we do not use customer proprietary designs in our marketing or case studies without explicit written permission. Many of our customer relationships are under NDA, and we have a proven track record of maintaining strict confidentiality over 20+ years of operation.

Ready to Start Your Custom Project?

Send us your design drawings, specifications or samples for a free DFM review and quotation within 24 hours. Our engineering team is ready to help you succeed.

Request a Quote →