Delivering Rugged, Customized Keypad Solutions for Utility Truck Applications

February 11, 2026

Customer & Application Overview

A leading manufacturer in the utility truck body industry—specializing in lifting booms and utility pole‑drilling vehicles—approached Marlin to solve a critical control‑interface challenge. Their trucks rely on exterior‑mounted keypads that allow operators to input commands directly into the vehicle’s control system.

These keypads face some of the harshest operating environments imaginable:

• Constant exposure to rain, snow, sleet, and high winds

• Temperature extremes from –40°F to +120°F

• Shock and vibration from heavy‑duty trucks traveling long distances

• Potential impact from gravel and debris on roadways

Despite these demanding conditions, the customer’s existing keypad supplier was struggling with long lead times and inconsistent delivery. They needed a reliable partner who could match the ruggedness and functionality of their current solution—while also providing customization and dependable supply.

Project Requirements & Constraints

The customer outlined several key requirements:

• Keypads must match the size, durability, and operational feel of their existing units.

• Custom button graphics and non‑standard indicator light colors were essential.

• Each keypad part number needed a specific CAN source address to ensure seamless integration into their control system.

These constraints required a supplier capable of both mechanical ruggedization and firmware‑level customization.

Why the Customer Chose Marlin

Marlin was selected for several reasons that aligned directly with the customer’s needs:

• Rapid customization: Marlin could modify keypad designs—including graphics, lighting, and firmware—within short lead times.

• Supply chain stability: Even during industry‑wide disruptions, Marlin could meet ongoing production demands.

• Strong reputation: The customer was referred by an internal colleague who had already worked successfully with Marlin on another project.

• Collaborative approach: The customer noted that Marlin was flexible, responsive, and easy to work with throughout the modification process.

Functional Safety Approach

To support global deployment, Marlin’s keypads had already undergone rigorous EMI/EMC testing and carried CE, UKCA, and CA certifications.

These tests were performed by specialized facilities to ensure compliance with international standards—giving the customer confidence that the keypads would meet regulatory requirements in multiple markets.

Engineering Challenges & Problem‑Solving

While the project was relatively straightforward, a few technical challenges required thoughtful engineering:

• Indicator light brightness: Changing LED colors required recalculating brightness levels to maintain visibility and consistency. Marlin engineers performed the necessary calculations and validated them through testing.

• CAN communication parameters: The customer requested specific message speeds and timing adjustments. Marlin updated the firmware to meet these requirements without impacting performance or reliability.

Innovation & Value‑Added Features

Marlin delivered several enhancements that improved usability and integration:

• Pre‑configured Source Addresses: Each keypad was programmed with customer‑specific CAN source addresses, simplifying system integration.

• Software refinements: Message timing, status reporting, and communication behavior were fine‑tuned to match the customer’s control architecture.

• Exceptional technical support: Marlin’s engineering team provided fast, knowledgeable assistance, ensuring a smooth implementation process.

Testing, Validation & Deployment

Marlin conducted extensive in‑house testing on all modified keypads before sending prototypes for customer evaluation. The customer performed both bench testing and on‑truck validation.

Whenever communication discrepancies or timing issues arose, both teams collaborated quickly—sharing data files and meeting virtually to resolve issues in real time.

The result was a smooth deployment process and a keypad solution that exceeded expectations in performance, durability, and ease of integration.

Final Results & Customer Benefits

The customer now benefits from a stable, flexible, and responsive keypad supply chain:

• Marlin has become their primary supplier, giving them a reliable second source and reducing risk.

• Inventory levels are consistently maintained, and additional production quantities are available as needed.

• Marlin holds finished‑goods inventory under a supplier agreement, ensuring minimal lead times and uninterrupted production.

Lessons Learned & Future Opportunities

This successful collaboration opened the door to broader engagement across the customer’s organization:

• Multiple engineering and manufacturing sites have since partnered with Marlin on new keypad designs.

• Marlin refined internal processes to accelerate modifications to standard products and streamline release‑to‑market steps.

•Ongoing projects now include not only Classic keypads but also Legend Series keypads, digital power distribution modules, control modules, and display systems.