Printed Electronics

In today’s technological-digital transition scenario, there is a growing demand for connected and interactive systems based on functionalized and/or sensorized surfaces. In this context, plastronics, also known as In-Mold Electronics (IME), is a new technology for manufacturing printed electronic devices embedded in plastic materials, providing high-value-added functions or features. Analyses and forecasts indicate that this technology will make electronics ubiquitous due to its wide range of applications in various sectors, such as:

This manufacturing technology consists of four main processes:

Printing

Printing conductive inks (such as silver, copper, or carbon) using techniques like screen printing or inkjet on a flexible plastic film (typically PC, PET, or other polymers). Multiple layers are generally printed, which may include conductive, insulating, and decorative circuits.

Hybridization

Mounting SMD components such as LEDs, resistors, microcontrollers, etc., onto the printed film using automated placement methods (Pick & Place).

Thermoforming

Once the entire electronic part is completed, the flat film undergoes a temperature and pressure or vacuum process to achieve the desired shape/geometry. This step is crucial to ensure that the electronics are compatible with curved or complex shapes that match the final design.

Overmolding

The thermoformed film is inserted into an injection molding mold. Plastic material (such as ABS, polycarbonate, or others) is injected onto the film, encapsulating the electronic circuits and creating a solid and durable final piece.

The result is a molded component with electronic circuits and components fully embedded in its surface or interior. The surface of the component can be interactive (e.g., touch panels) and may include additional features such as backlighting or LED signaling.

Automotive

This is the most demanding sector (80%) and the driving force behind the development of embedded electronics via IME for applications in displays, capacitive touch sensors, vehicle detection systems, instrument panels, ambient lighting, and any aesthetic-functional interior or even exterior vehicle parts. This technology is also relevant for electric vehicles due to its weight reduction compared to conventional electronics and the possibility of replacing wiring with printed circuits.

Home Appliances

White Goods: The second most demanding sector for this technology (10%), with its main application in high-aesthetic-quality touch controls on appliance front panels.

Health and Well-being

The third most demanding sector (4%), currently a key focus of research centers and several companies across Europe. Applications include patches for pain relief or sensors that can be attached to the patient’s body to monitor various health parameters. In terms of well-being, embedded electronics are found in wearable devices for sports and fitness.

Construction

Sensors and RFID (radio frequency identification) components are used in various IoT applications. One example is smart buildings, which continuously measure quality, temperature, or humidity levels and communicate data to the building automation system.

Energy and Photovoltaics

Flexible photovoltaics can be used as a sustainable energy source for both indoor and outdoor applications. These systems can be easily integrated into products of various shapes and sizes. Although Europe is not strong in the current crystalline photovoltaic market, it can position itself in the flexible photovoltaics sector. Embedded electronics are also useful for other energy applications, such as batteries and capacitors, which are currently in the development phase.

Smart Packaging

Smart packaging is a mature application that uses RFID and NFC systems for traceability/logistics or product status detection, in combination with various types of sensors.