Custom Automation Touchscreen Displays: When Standard HMI Is Not Enough

 

Industrial automation is becoming more connected, compact and application-specific. Machine builders and OEMs are increasingly expected to deliver equipment that is easier to operate, more reliable and better suited to the customer's production environment. In many cases, the Human-Machine Interface (HMI) plays an important role in achieving this.

A standard HMI can be an excellent solution when the machine fits within its available display sizes, mounting options, touch technology and interfaces. But when the machine has specific mechanical, electrical or environmental requirements, adapting a standard product can become difficult and expensive.

This is where custom automation touchscreen displays can provide a better solution.

Instead of designing the machine around an existing HMI, a custom touchscreen display can be developed around the machine itself.

What Is a Custom Automation Touchscreen Display?

A custom automation touchscreen display is an industrial display or HMI developed or configured specifically for a particular machine, automation system or OEM application.

Customization can involve much more than changing the screen size. Depending on the project, it may include:

• Display size and resolution
• PCAP or resistive touchscreen technology
• Cover glass
• Brightness
• Optical bonding
• Housing and bezel
• Mounting method
• Connector positioning
• Embedded electronics
• Processor and memory
• Communication interfaces
• Operating temperature
• IP protection
• Branding and front-panel design

The objective is to create an HMI that fits the machine's technical and operational requirements rather than forcing the machine builder to compromise around an off-the-shelf product.

Why Standard HMIs Are Not Always Enough

Standard industrial HMIs are designed to address common requirements across a broad range of applications. They are often available in predefined sizes and configurations, which makes them practical for many automation projects.

However, OEM equipment can have very specific requirements.

For example, a machine may have a limited installation space where a standard 10-inch or 12-inch panel does not fit. Another machine may require a particular aspect ratio, connector arrangement or mounting system.

A standard HMI may also include features that are unnecessary for the application while missing a feature that is essential.

This can lead to compromises in machine design.

Instead of asking:

"Which standard HMI fits our machine?"

OEMs can ask:

"What HMI does our machine actually require?"

That change in approach is one of the main reasons custom industrial display development can make sense.

When Should You Consider a Custom Touchscreen?

Not every automation project needs a custom display. A standard industrial HMI is usually the most efficient choice when it meets the application's requirements.

Customization becomes more attractive when several specific requirements need to be combined.

1. Your Machine Has Limited Installation Space

Space inside industrial machinery is often limited.

A standard HMI may be too large, too deep or have mounting dimensions that don't work with the machine's existing structure.

A custom display can be designed around the available space.

This can be particularly useful for:

• Compact automation equipment
• Packaging machines
• Laboratory equipment
• Mobile machinery
• Robotics
• Inspection equipment
• Embedded control systems

The display can be engineered around the mechanical architecture rather than forcing changes to the machine enclosure.

2. You Need a Specific Screen Size or Aspect Ratio

Standard industrial displays typically come in predefined sizes.

But some applications require a non-standard format.

For example, an OEM may need:

7-inch wide display

10.1-inch compact display

12-inch portrait display

stretched display

or another application-specific format.

A custom display can provide greater flexibility in selecting the display dimensions and aspect ratio.

This is particularly valuable when the HMI needs to fit into an existing machine panel or a custom operator station.

3. You Need a Specific Touch Technology

The choice between PCAP and resistive touch depends on the application.

PCAP is often preferred for modern interfaces because it provides a glass surface, responsive operation and multi-touch capabilities.

Resistive touch can be advantageous where operators use heavy gloves, styluses or require pressure-based operation.

A custom HMI allows the touchscreen technology to be selected according to the actual operating environment.

For example, a food-processing machine may have very different touchscreen requirements from a laboratory instrument or a factory automation panel.

4. Operators Need to Use Gloves

Glove operation is a common requirement in industrial environments.

Operators may wear protective gloves for safety, hygiene or handling requirements.

A touchscreen designed primarily for bare-finger operation may not perform adequately with every type of glove.

A custom touchscreen project can take glove operation into account during the design and validation process.

The actual glove type, cover glass, sensor and touch controller can be evaluated together rather than assuming that generic touchscreen specifications will be sufficient.

5. The Machine Operates in a Harsh Environment

Industrial equipment can be exposed to:

• Dust
• Water
• Oil
• Cleaning agents
• Vibration
• Temperature changes
• Electromagnetic interference

In these environments, the display needs to be designed as part of the machine's overall protection strategy.

A custom solution can consider the enclosure, sealing, front glass, connectors, mounting and thermal design together.

For applications requiring frequent cleaning or washdown, the mechanical construction of the HMI can be particularly important.

6. You Need a Specific IP Protection Level

The required IP protection depends on the environment in which the HMI will be installed.

An HMI mounted inside a protected control cabinet does not necessarily require the same protection as one installed directly beside a food-processing machine.

A custom display project allows the environmental requirements to be defined at the beginning.

The engineering team can then consider:

• Enclosure design
• Sealing
• Connectors
• Front surface
• Mounting
• Cable routing

This can result in a more appropriate solution than attempting to modify a standard product after the machine has already been designed.

7. You Need Specific Interfaces

Industrial machines often use a combination of communication and video interfaces.

Depending on the application, an HMI may need:

• HDMI
• DisplayPort
• VGA
• USB
• Ethernet
• RS-232
• RS-485
• CAN
• Digital I/O

A standard display may not provide the required combination or connector positioning.

Custom electronics can provide greater flexibility in integrating the required interfaces.

This can simplify machine integration and reduce the need for additional converters or interface boards.

8. You Need Long-Term Product Availability

Long machine lifecycles are common in industrial automation.

A machine builder may continue manufacturing a product for many years. Customers may also expect spare parts to remain available throughout the machine's service life.

Consumer displays can change quickly, making long-term availability difficult.

A custom industrial display project can take lifecycle requirements into account from the beginning.

For OEMs, this can help with:

• Product continuity
• Replacement planning
• Component management
• Future revisions
• Spare parts
• Maintenance

Long-term availability should therefore be considered part of the HMI specification rather than an issue to solve after production begins.

Custom HMI vs Standard HMI

The choice between standard and custom should be based on the requirements of the machine.

Requirement	Standard HMI	Custom HMI
Standard screen size	Excellent	Excellent
Fast deployment	Excellent	Depends on project
Fixed mounting	Good	Excellent
Specific dimensions	Limited	Excellent
Custom housing	Limited	Excellent
Specific connectors	Depends on model	Excellent
Special touch requirements	Depends on model	Excellent
OEM branding	Limited/varies	Excellent
Application-specific design	Limited	Excellent
Long-term customization	Depends on supplier	Excellent
Development cost	Lower initially	Higher initially
High-volume OEM production	Good	Often attractive

The important point is that custom does not automatically mean better.

If an existing industrial HMI already meets the requirements, there may be no reason to develop a custom solution.

Customization becomes attractive when the benefits of a purpose-built solution outweigh the additional engineering effort.

The Hidden Cost of Adapting a Standard HMI

At first, an off-the-shelf HMI can appear to be the cheaper option.

But if the product doesn't fit the machine properly, additional engineering may be required.

For example, an OEM might need to redesign:

• The mounting panel
• The enclosure
• Cable routing
• Internal brackets
• Power connections
• Communication interfaces
• Software interface

These modifications can increase engineering time and production complexity.

A custom HMI may have a higher initial development cost, but it can reduce compromises elsewhere in the machine.

Therefore, OEMs should compare the total development and integration cost, not just the purchase price of the display.

Custom Touchscreen Displays for OEM Machine Builders

OEMs often develop machines for a specific industry or customer requirement.

The HMI becomes part of the machine's identity and operator experience.

A customized touchscreen can support the OEM by providing:

Consistent design

The same display architecture can be used across different machine models.

Better integration

The display can fit the mechanical and electrical design more naturally.

Improved operator experience

The interface can be designed around the machine's actual workflow.

Product differentiation

A custom HMI can make the machine look and feel different from competing equipment.

Future scalability

The display platform can potentially be adapted for future machine generations.

Applications Where Custom Automation Touchscreens Make Sense

Custom touchscreen displays can be useful across many industrial sectors.

Industrial Automation

Machine control, production lines and automated equipment often require reliable operator interfaces with specific mounting and communication requirements.

Food Processing

HMI systems may need hygienic construction, easy cleaning and suitable touchscreen operation.

Packaging Machinery

Compact displays and application-specific mounting can be useful where machine space is limited.

Medical Equipment

Medical and laboratory systems may require specialized display sizes, touch technologies, brightness and cleanable surfaces.

Robotics

Robotic systems can benefit from compact displays and application-specific operator interfaces.

Transportation

Displays used in vehicles and transportation systems may need extended temperature ranges, high brightness and rugged construction.

Energy and Infrastructure

Control systems may require high reliability, long-term availability and specialized interfaces.

What Should You Give an HMI Development Partner?

Before starting a custom touchscreen project, OEMs should define the application requirements as clearly as possible.

Important information includes:

Display

What screen size, resolution and brightness are required?

Touch

Should the system use PCAP or resistive touch? Will operators wear gloves?

Environment

What temperatures, humidity, dust, water and chemicals will the display encounter?

Mechanical

What are the available dimensions and mounting requirements?

Electrical

What power supply and interfaces are required?

Software

Which operating system, HMI software or communication protocols need to be supported?

Lifecycle

How long will the product need to remain available?

Quantity

Is the project a low-volume prototype or a high-volume OEM product?

Providing these requirements early can make the development process more efficient.

Why Work With an Engineering-Focused Display Partner?

Custom HMI development is not simply about selecting an LCD panel.

The final solution may involve:

Display engineering + touch technology + electronics + mechanics + software + testing

This is why OEMs can benefit from working with a partner capable of managing multiple aspects of the development process.

An experienced industrial display engineering partner can help evaluate the application, recommend suitable technologies, develop prototypes and refine the solution before production.

Why T&O Electronic Solutions for Custom Automation Displays?

For OEMs and machine builders looking for application-specific industrial display solutions, T&O Electronic Solutions provides customized HMI and display development focused on demanding industrial applications.

T&O can support projects involving industrial touch displays, HMI systems, embedded electronics and application-specific display integration.

The focus is not simply on supplying a screen. The objective is to develop a display solution that fits the machine's technical requirements and the operator's workflow.

This approach can be particularly valuable when a standard industrial monitor does not provide the required combination of size, touch technology, mechanical design, interfaces, environmental protection or customization.

Questions to Ask Before Buying a Custom HMI

Before contacting an industrial display supplier, ask:

Does a standard HMI genuinely meet our requirements?

If yes, a standard product may be the most practical solution.

What requirements cannot be met by standard products?

These become the starting point for customization.

Will the HMI be used with gloves?

If yes, touch technology needs to be evaluated accordingly.

Will it be exposed to water or cleaning chemicals?

This determines the required mechanical and environmental design.

How long will the machine remain in production?

This affects component selection and lifecycle planning.

Do we need custom mechanical or electrical integration?

If yes, an engineering-led HMI supplier can provide additional value.

Conclusion

Standard HMIs remain an excellent choice for many automation applications. They are readily available, proven and often cost-effective.

However, they are not always the right solution for specialized OEM machinery.

When a machine requires specific dimensions, custom mounting, specialized touch technology, glove operation, environmental protection, unique interfaces, long-term availability or application-specific integration, a custom automation touchscreen can provide a better approach.

The decision should ultimately be based on the complete machine—not simply the price of the display.

For OEMs and machine builders, a properly engineered custom HMI can become an integral part of the equipment, improving integration, usability and product differentiation while providing greater control over the machine's long-term design.