Custom Front Overlays and membrane keyboards for ATEX Applications
A conventional plastic graphic overlay can create an electrostatic charging risk. For this reason, front overlays used on equipment for hazardous areas may require a specifically designed construction to support the electrostatic safety requirements of the equipment.
FLEXTEC offers custom front overlay solutions for equipment intended for ATEX and Ex applications, combining industrial durability, customized graphics, display windows and electrostatic charge control.
Why are front overlays important in ATEX applications?
Potentially explosive atmospheres can occur where flammable gases, vapours, mists or combustible dusts are present. The European ATEX Directive 2014/34/EU covers equipment and protective systems intended for use in these environments. Eur-Lex
One potential ignition risk is electrostatic discharge.
Polyester and polycarbonate, commonly used for industrial graphic overlays, are electrically insulating materials. Under certain conditions, an exposed insulating surface can accumulate electrostatic charge.
For this reason, the electrostatic properties of external non-metallic parts have to be considered when designing equipment for explosive atmospheres.
The current IEC 60079-0:2026 standard specifies general requirements for the construction, testing and marking of Ex Equipment and Ex Components. IEC Webstore
FLEXTEC solutions for ATEX front panels
FLEXTEC can manufacture customized front overlays specifically designed to support the electrostatic requirements of Ex equipment.
Depending on the application and required classification, we can provide solutions incorporating:
electrostatic charge control and connection to the equipment's grounding or equipotential bonding system;
transparent areas for LCD, LED and other displays;
chemically resistant external surfaces;
abrasion-resistant surfaces for industrial use;
custom colours, symbols, logos and operating instructions;
transparent or tinted indicator windows;
adhesive mounting to metal or other suitable front panels;
custom shapes, openings and cut-outs.
The exact solution is selected according to the requirements of the final equipment.
Solutions for demanding gas groups
For applications where particularly stringent electrostatic requirements apply, FLEXTEC can offer constructions with a very thin insulating section between the exposed surface and the grounded conductive system.
Solutions can be designed with an insulating thickness of less than 0.2 mm, allowing them to be considered for demanding applications including gas group IIC, subject to the classification and conformity assessment of the complete equipment.
The conductive system can also be designed to provide a defined connection to the equipment grounding system, enabling controlled dissipation of electrostatic charge.
This makes it possible to combine the electrical requirements of an Ex application with the functionality expected from a modern industrial user interface.
Transparent display windows
Displays are often one of the most difficult areas when designing an electrostatic-safe front overlay.
A conventional transparent window is electrically insulating, while replacing it with an opaque conductive material would obviously make the display unusable.
FLEXTEC can provide transparent window solutions while maintaining electrostatic charge control across the required area.
This makes the technology suitable for equipment incorporating:
LCD displays, OLED displays, LED indicators, status displays and other optical user interfaces.
The operator therefore retains clear visibility of the display without sacrificing the electrostatic design requirements of the front panel.
Chemical and mechanical resistance
ATEX equipment is frequently used in demanding industrial environments such as chemical processing, petrochemical plants, manufacturing facilities and process-control installations.
The front overlay can therefore be specified not only for electrostatic performance but also for environmental resistance.
Depending on the application, FLEXTEC can provide surfaces designed for resistance against commonly encountered chemicals, cleaning agents, oils and industrial contamination, together with good abrasion and wear resistance.
The graphic elements are also designed for long-term industrial use.
Fully customized front panel design
ATEX requirements do not mean that the equipment has to compromise on user-interface design.
The overlay can be completely customized to the customer's equipment, including:
dimensions, colours, display windows, transparent areas, warning symbols, Ex markings, company branding, button positions and custom cut-outs.
The solution can therefore be integrated into new equipment or adapted to an existing front-panel design.
ATEX compliance and the complete equipment
It is important to distinguish between an ATEX-certified piece of equipment and an overlay designed to support the ATEX compliance of that equipment.
FLEXTEC supplies the customized front overlay as part of the customer's equipment design. The final ATEX classification and conformity assessment applies to the complete equipment and depends on its intended environment, construction and protection concept.
The ATEX Directive requires equipment and protective systems to be designed with consideration for foreseeable ignition hazards and specifies essential health and safety requirements for equipment intended for potentially explosive atmospheres. Eur-Lex
For this reason, we work from the customer's required Ex specification rather than applying a universal ATEX classification to every overlay.
Information required for an ATEX front overlay
When requesting a quotation, it is useful to provide the intended gas or dust environment, equipment group/gas or dust group, Zone or Equipment Protection Level (EPL) and any specific electrostatic requirements defined for the equipment.
If these parameters are not yet finalized, FLEXTEC can discuss the front-overlay requirements during the design stage.
Custom manufacturing in Hungary
FLEXTEC manufactures custom industrial front overlays and membrane switch solutions in Hungary, supporting both prototype development and serial production.
Our ATEX-oriented front overlay solutions make it possible to combine:
electrostatic safety + transparent displays + chemical resistance + industrial durability + customized graphics
in a single user-interface solution.
Looking for a custom front overlay for an ATEX application?
Send us your drawing, front-panel design and required ATEX/Ex classification.
FLEXTEC can help develop a customized front overlay solution suitable for integration into your Ex equipment.
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