A key pain point for electronic device manufacturers has long been the traditional metal dome assembly process, which relies on FPC (Flexible Printed Circuit) for connection to PCBs (Printed Circuit Boards). This approach increases assembly steps, material costs, and potential failure risks at the FPC-PCB interface. When a leading consumer electronics client approached Shanyo with a demand for a metal dome that could be directly welded to PCB, Shanyo's R&D team rose to the challenge and developed the 4535 series.
The core challenge of direct PCB welding lies in balancing the metal dome's structural integrity with welding compatibility. Conventional metal dome materials and designs are prone to deformation or conductivity loss under welding temperatures. Shanyo optimized the 4535 series by adopting a high-temperature-resistant SUS301 variant and integrating a precision-weldable tab structure. The tab's surface is treated with a tin-plating layer to ensure strong solder adhesion to PCB pads.
The 4535 series retains the tactile feedback and durability of traditional metal dome while eliminating FPC dependency. After prototype development, the client conducted rigorous validation: high-temperature welding tests confirmed no deformation, and 100,000-cycle durability tests showed stable performance. Electrical conductivity tests verified consistent signal transmission between the metal dome and PCB, fully meeting operational requirements.
This innovation streamlines production for the client, reducing assembly time by 30% and material costs by 20%. Shanyo's 4535 series sets a new standard for metal dome-PCB integration, demonstrating how customer-centric R&D solves industry-specific assembly bottlenecks.