CNC Laser Cut & Etched Polycarbonate Overlay with Dead-Front Graphics for the Aerospace Industry

A customer in the aerospace industry was in need of a custom front panel overlay, which was to be used in an aircraft display application. This product features dead-front graphics; which are graphics that only appear when illuminated. The paint system used allows for flexibility without cracking and was applied to meet customer specifications for light transmittance.

Manufacturing of this item required the use of a various precision fabrication capabilities, the overlay and PSA backing were laser cut on our CNC CO2 laser, with spray paint applied in our spray booth with a fine-detail spray gun. The overlay was also fiber laser etched on our Ytterbium fiber laser, the finished overlay was also oven baked and cured, then assembled.

Through the manufacturing process, the panel was subject to stringent quality control measures. Prime Products produced over 10,000 of this item for an aerospace customer in Kansas.

For more information on the complex fabrication processes and materials used on this product, see the table below or contact us directly.

CNC Laser Cutting & Etching Project Highlights

Product Name

Front Panel Overlay

Product Description

This Front Panel Overlay is used on an aircraft display panel.

Capabilities Applied/Processes

CNC Laser Cutting
Spray Painting
CNC Fiber Laser Etching
Screen Printing
PSA Assembly

Plasma Treating
Touch Up

Equipment Used to Manufacture Part

CNC CO2 Laser
Plasma Jet
Spray Paint Booth with Fine-Detail Spray

Ytterbium Fiber Laser
Screen Print Workstation
Batch Oven

Overall Part Dimensions

3.709″ Long x 0.877″ Wide x 0.020″ Thick

Tightest Tolerances


Material Used

Lexan 8010 Clear Polish/Polish .020″
Black Epoxy Nazdar ADE52
Proprietary Dead-Front paint system

White Epoxy Nazdar ADE751K
Clear Matte Polyurethane Mix
3M 9690B Sheet (Liner Added)

Material Finish

Front Surface Matte Dead-Front
Rear Surface Polished
Nomenclature Light Transmittance 15-22%

Graphics Light Transmittance 7-13%
Opaque Black per FED-STD-595 Color #37038
Translucent White per FED-STD-595 Color #37875

In process testing/inspection performed

Dimensional Inspection
CMM Inspection
Photometer Light Transmission

Visual Inspection
Final Inspection

Industry for Use



250 per year

Delivery/Turnaround Time

7 Weeks

Delivery Location

Olathe, Kansas

Standards Met

PDF Drawing Specifications
Material Specifications
Light Transmission Specifications
FED-STD-595 Color Specifications

2D CAD Artwork
Certificate of Compliance
AS9102 First Article Inspection Report

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