Real World Panels on DZUS Rails, question | MobiFlight | Page 1

spark willow Apr 3, 2026, 2:29 PM

#

Just out of curiosity, does anyone know exactly how this might work in real commercial aircraft? I'm working on my 737 center pedestal, and with the Navigation Radio panel, wouldn't the actual DZUS rails interfere with the buttons on the left? Even the real panels aren't really that thick, I think maybe 6mm? I suppose maybe they have components and/or manufacturing capabilities that I just don't, but I'm still curious.
Also, at least in terms of my panel recreation, to get LEDs behind the "NAV" text for backlighting, my PCB would end up being in the way of fastening to the rails. I'm just trying to brainstorm a little deeper on this.

spiral mauve Apr 3, 2026, 2:55 PM

#

The panel and the fasteners have some thickness, it is possible to assemble a mechanism shallow enough to sit above the rails

#

Failing that, the button caps can be put on levers that actuate switches placed in areas with more depth clearance available

spark willow Apr 3, 2026, 4:45 PM

#

I could absolutely embed the PCBA into the panel with these switches instead of the through-hole version of them, but man are they expensive. But yea, I can see insetting the PCBA into the panel layers.

rancid flame Apr 3, 2026, 5:56 PM

#

I know @thorn tree has his panels created from 3 layers of 3mm acrylic. I havent bothered yet, but this is a way to have some space inside, so you have 6mm to play with

#

also an option then, is to have the PCB itself be the mounting plate with screw holes

#

so its all stacked together without standoffs, the bottom most acrylic panel would just have a bigger cutout inside

#

that way you could also backlight the side "NAV" text etc

#

also, use tactile buttons and small leds on sides

#

@spark willow as long as the buttons are white pla or something else that passes light through, it also works from the side

spark willow Apr 3, 2026, 6:11 PM

#

The SMD switch above is on the left. The same switch but through-hole version is on the right. The stackup on the panel design at this point is 7mm.

#

I'm still messing around with the design to see which way to go. Using the PCB itself as the backplate is kind of an interesting idea.

rancid flame Apr 3, 2026, 9:10 PM

#

I use KD2 switches

#

no wait that is different one

#

KSC241JLFS

#

similar are found on AliExpress and can be hand soldered with care

spark willow Apr 3, 2026, 11:54 PM

#

rancid flame KSC241JLFS

How do you manage to backlight your buttons when using these?

rancid flame Apr 3, 2026, 11:59 PM

#

#

spark willow Apr 4, 2026, 12:22 AM

#

Hmm, very interesting

#

Those buttons must be resin printed

rancid flame Apr 4, 2026, 12:23 AM

#

pla would also work but resin looks nicer

#

white print + paint + engrave

spark willow Apr 4, 2026, 12:23 AM

#

Just trying to figure out how you'd support that void without it being filled with support material that would be next to impossible to remove

rancid flame Apr 4, 2026, 12:25 AM

#

I think it will print fine without

#

the center bulge on the bottom of void is a bit impossible

#

if printed upside down yeah

#

or maybe even that would bridge sideways

spark willow Apr 4, 2026, 12:26 AM

#

The density of the buttons on this navigation panel would make fitting LEDs beside each button quite a challenge

rancid flame Apr 4, 2026, 12:27 AM

#

yes, though those switches are smaller?

#

or maybe not

spark willow Apr 4, 2026, 12:27 AM

#

Quite probable, let me see how they compare size-wise

rancid flame Apr 4, 2026, 12:28 AM

#

or use the basic button, its tiny

spark willow Apr 4, 2026, 12:28 AM

#

Yea, they're a bit smaller. 6.2mm for the ones you linked, 9.8mm for the illuminated ones I have on the board now

rancid flame Apr 4, 2026, 12:29 AM

#

anyway, got to sleep 🙂 night!

spark willow Apr 4, 2026, 12:29 AM

#

Night!

rancid flame Apr 4, 2026, 12:29 AM

#

yea that likely fits leds in the corners for example

spark willow Apr 4, 2026, 5:35 PM

#

Hey @rancid flame, in your experience using this method for backlighting your buttons, do you think I'd have good enough coverage with 1 LED in between each button set like this or should I add more than this?

rancid flame Apr 4, 2026, 5:48 PM

#

I would maybe put on tbe top and bottom too do each button gets the same amount of light

#

even if it was visible with one led, it would be brighter with two

#

might also work in corners

#

you could try with regular LED's pushed through cardboard and panel on top

#

to see what works and how the light travels. it is an interesting topic in itself

#

on the gnc255 I have leds between buttons horizontally like

L B L B L B L B

#

the g3x has buttons so far apart that I have two LEDs vertically, one above and one below

#

like on the above photo

spark willow Apr 4, 2026, 5:55 PM

#

Fair enough. I'll order some parts and give this a test run before I commit to a PCBA. Thanks.

rancid flame Apr 10, 2026, 6:30 PM

#

share your prototyping findings if you want, its always interesting

spark willow Apr 12, 2026, 7:11 PM

#

#

I've just completed my Nav Panel button set (don't mind the blank one... it was extra). I put on a LED on my benchtop power supply and held the button off to the side of it and the result was good. I'm confident this method will work. I'm going to order some of those switches off Digikey now (this is surprisingly one of those times ordering from Aliexpress doesn't save any money at all), plus I need some more SMD LEDs anyways, so then I can make sure the buttons fit over the switches, then I'll probably do my PCBA order.

#Real World Panels on DZUS Rails, question