Engraved Electrical Panel Traffolyte Labels
Traffolyte (also written Traffolite) is a multi-layered composite sheet material made from phenol‑formaldehyde resins (PF). When machine engraved, the layered construction creates high‑contrast, long‑lasting text and symbols — making it ideal for use inside and outside electrical cabinets and enclosures.
Origins and material properties
Traffolyte dates back to 1927 when it was first produced by Metropolitan‑Vickers Electrical Ltd in Manchester, UK, originally for engraved transformer labels. The material is electrically non‑conductive and heat resistant, properties which suit electrical labelling applications very well.
Important safety note: the phenolic dust produced when engraving traditional Traffolyte is now recognised as a health hazard, so appropriate precautions are required when routing or engraving this material. Newer alternatives and engraving methods have reduced this risk.
How Traffolyte engraving works
Classic Traffolyte sheets are layered so that a thin top colour covers a contrasting colour beneath. When a routing tool removes the top layer, the underlying colour is revealed — producing crisp, highly legible engraved text and symbols.
Early engraving used pantographs; modern production typically uses CNC routing tables with floating heads. The floating head allows the cutter to follow uneven surfaces while maintaining the correct depth. The cutter depth must fully penetrate the top layer to expose the contrasting layer below. CO₂ laser engraving is also used for some products, producing similar results (with a different edge finish than routed work) and avoiding the phenolic dust issue.
Colours, thicknesses and configurations
While the original two‑colour black & white configuration was common, traffolyte-style materials are now available in many colours and ply combinations. Typical thickness options range from very thin 0.2 mm two‑colour sheets up to 3 mm in three‑ply (three‑colour) formats.
Engraved traffolyte labels are:
- Scratch resistant
- UV stable
- Weather resistant
Applications
These attributes make multi‑layer engraved labels suitable for a wide variety of uses, including:
- Caution labels and warning labels
- Compliance and identification plates
- Control and operator instruction plates
- Electrical and switchboard labels
- Indicator light and push‑button legends
- Selector switch labels, key tags, and mining equipment labels
Mounting and mechanical considerations
Historically, traffolyte sheets were quite stiff and brittle and required mounting to flat surfaces, often using M3 or M4 bolts through mounting holes created at the time of engraving. Modern materials are more flexible — thinner sheets can even be rolled around objects — increasing their versatility.
For electrical switchboards, a common and preferred mounting method is to provide multiple 1/8″ (approx) mounting holes and attach the labels with plastic plugs, rivets, or screws (the method should be specified in the job specification). Note that double‑sided tape can fail over time due to heat inside switchgear or enclosures, so adhesive mounting is not recommended for high‑temperature environments.
Custom shapes and production
Traffolyte and traffolyte‑style labels can be produced in standard shapes or custom/irregular shapes. For accurate quoting and production of irregular shapes we typically request vectorised artwork (for example a .dxf or other vector file). Hand‑drawn shapes can be scanned and vectorised in design software if required.
Material advancements
As alternatives to the original branded “Traffolyte” have entered the market, the term has become a generic descriptor for this class of multi‑layer engraved labels. Newer products address earlier health risks and provide options that are laser‑engraveable or more flexible while maintaining the desirable electrical and environmental properties.
Need engraved labels?
Koalabel has over 15 years’ experience supplying durable engraved labels and identification solutions across Australia and New Zealand. We can produce customised engraved panel labels in a wide range of colours, thicknesses and shapes, suitable for electrical panels, safety signage and industrial applications.
If you would like a quotation or to discuss material and mounting options, please use our website contact form to submit artwork and requirements. Provide any vectorised drawings where possible to speed up the quoting process.
Key considerations when ordering:
- Specify material colour(s) and ply (two‑colour, three‑colour, etc.).
- Confirm label size and quantity.
- Provide vector artwork (.dxf, .ai, .eps) for custom shapes.
- State the preferred mounting method (screws/rivets, mounting holes, etc.).
- Note any environmental conditions (temperature, UV exposure) so the correct material can be specified.
Durable, legible and long‑lasting — traffolyte‑style engraved labels remain one of the most cost‑effective ways to identify equipment, controls and safety points in demanding environments.