What I wanted was a die cut, backprinted piece of textured polycarbonate, like you would use for an overlay for the front panel of an equipment enclosure. There are lots of label printing companies that can make you a graphic overlay type part, and I especially wanted the embossed button areas. But in the end I used Maverick Label to prototype my idea since they are pretty affordable, offer online real time quotes, and fast prototype service. I did the design of the button area in Autocad and Illustrator and uploaded my files. About a week later, I had the parts.

They looked pretty good, though the printing was a bit marginal if you look too close. My friend JD says this is typical of the 'digital screen printing' resin print process used to make prototypes like this. Anyways, I got their 'Lexsaver' product, which has the printing done on a thin layer of PET, and then laminated to the back of a polycarb sheet, with adhesive on the back of the die cut parts as well.

I designed the case so the label sits in a milled out pocket on the front of the device, ideally sitting flush with the surface of the case. I will need to lasercut some plastic posts to stick to the bottom of the label to act as actuators for the SMT buttons inside.

Proof image from Maverick

The front metal sheet is glued or laminated with sheet adhesive to the core, and the back is held on by 2-56 stainless flat head torx screws run into threaded laser cut holes in the core section. The label for the buttons in dropped into the pocket in the front piece. Both the front and back need pockets milled on the inside to accomodate the internal components. An acrylic window is incorporated in the back, for the radio antenna to sit under (it wouldn't work very well if you put it in what is essentially a metal box).

My first try is with clear anodized finish on front and back with label colors as shown. I also want to try clear anodized back with black anodized front and an inverse color label.