A keycap legend that never fades is not printed onto the plastic. It is grown inside it.
Double shot injection moulding builds a single keycap from two separate injections, in two separate cavities, without the part ever leaving the machine.
The sequence:
- Shot one fills the legend cavity, forming the character as a solid slug of resin
- The index plate rotates 180 degrees, carrying the part on its core
- Shot two injects the outer shell around it, filling every void the first shot left
- The two melts fuse at the interface under heat and injection pressure
The result is a character with genuine depth. The legend is not a coating sitting on the surface. It runs down through the wall of the cap. Abrasion attacks both plastics at the same rate, so the character stays legible long after the surface texture has polished smooth under a fingertip.
The hard part is the counters. The enclosed void inside an O, an A or a Q would float free, with no path connecting it to the rest of the leg...
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