Membrane switches vs. mechanical switches

Most mechanical switches are composed of copper and plastic. Copper has become a popular material for manufacturing mechanical switches because it’s highly conductive, reasonably inexpensive, and easy to source. Mechanical switches are fairly complex because they have a number of parts, such as a housing, an actuator, a spring, and electrical contacts. The actuation is typically achieved by pressing the actuator, which moves the electrical contacts together to complete the circuit.

Alternatively, membrane switch manufacturing usually incorporates an electric conductive ink (generally made with copper, silver, or graphite) printed onto a substrate made of indium tin oxide (ITO) or polyethylene terephthalate (PET). To actuate a membrane switch, the user presses the top layer, which causes it to make contact with the conductive traces on the bottom layer and complete the circuit. For more information about NMG capabilities as a mechanical switch and membrane switch manufacturer, visit our website.

One easy way to differentiate a membrane switch from a mechanical switch is that a membrane switch is flexible, while a mechanical switch isn’t. In fact, ASTM International (which develops technical standards) includes flexibility as a key component of its definition of a membrane switch: “a momentary switch device in which at least one contact is on, or made of, a flexible substrate.” A membrane switch’s flexible circuit allows it to bend and flex, whereas a mechanical switch can’t. This makes membrane switches more appropriate in certain applications.

Mechanical switches are known for their tactile feel and feedback. They offer a satisfying "click" or "bump" when the actuation point is reached, providing a clear indication that the keypress has been registered. Membrane switches, in general, have a softer and quieter actuation with less pronounced tactile feedback. While domes can be added into the membrane switch assembly to increase the tactile feel, the keypress will generally be softer and smoother than that of a mechanical switch.

Because they can be sealed closed, membrane switches are more protective against moisture and other contaminants—and can therefore achieve higher IP ratings. Oftentimes the top layer of a membrane switch is waterproof, and a properly sealed membrane switch can keep water, dust, etc. from getting inside. If you need a water resistant switch, consider a special type of membrane switch with a Kapton flex circuit. A Kapton circuit uses copper and polyimide instead of silver to increase the current capacity and moisture resistance of the switch versus a traditional membrane or mechanical switch.

As mentioned above, mechanical switches are fairly complex and include a number of components. Because membrane switches are easier to design and have fewer parts, they are less expensive to manufacture. In addition, the materials and manufacturing processes used to make membrane switches are typically less expensive than those used in mechanical switches. Add that assembly of a membrane switch is generally quicker than that of a mechanical switch, and the cost savings increase further.

While membrane and mechanical switches can serve the same purpose, their differences make both switches a good fit in certain applications. For example, mechanical switches are commonly used when precision and tactile feedback are important, such as mechanical keyboards, gaming peripherals, and some industrial control panels. Membrane switches are often used in applications where cost-effectiveness, low-profile design, and resistance to environmental factors like dust and moisture are critical. Common applications include consumer electronics, medical devices, and appliances.

Looking for help with your mechanical or membrane switch manufacturing? Nelson Miller Group provides engineering design, manufacturing, and supply chain support for all your switch needs. Contact us to learn more!