Advocates say plastic/printed electronics will revolutionise the electronics industry, whereas cynics insist this is ‘blue sky’ technology and it will, in any case, move to low cost countries. Intellect’s first Plastic Electronics Conference will be held next month, and attempt to give attendees a realistic feel for timescale and current barriers to growth. Printed circuitry can be used to place electronics on compact, inexpensive and lightweight substrates, reducing costs and size. Displays, batteries, transistors, and interconnects are among the technologies that can be produced on paper, plastics and other thin materials. However, whilst the media and general public is captured by the possibilities of low costs goods that have odd shapes and sizes (even fitting in clothes) technologists realise that the many categories lumped under the broad banner of plastic/printed electronics are still far from production. These designs can include disposable products such as glucose test strips and medical patches but, as Plastic Logic has quickly learned, one of the main challenges facing this fledgling market is pricing. That means product and business developers will have to examine tradeoffs – and that’s exactly one of the issues the event will try to address.
As technology changes are forcing requirements for low cost, low carbon and flexible applications, plastic/printed (or organic and large area) electronics have emerged with some of the most efficient techniques by which to achieve these goals. While development is still in its early stages, the technology may have the potential to dramatically change the electronics industry. The list of devices that rely on plastic/printed electronics technologies is big and getting bigger. Applications include touch screens, RFID antennae, medical sensors, flexible circuits, solar cells and so on. If we include smart packaging, lighting, optical signal processing and various applications available to retailers, the potential is truly enormous. In addition to consumer products, there are also big prospects in the automotive and aerospace industries. American engineers at Boeing, for example, are already experimenting with printed electronics technology to reduce weight, maintenance and cost of aircraft. In fact, the new 747-8 plane incorporates a partly printed bird-strike damage detection sensor.
As one of the most cost-effective production methods, plastic/printed electronics is enabling the high volume, high throughput, low cost paradigm. In fact, integrating several electronic functions (eg. sensors and antennae) which previously had to be applied as separate components, cuts the number of parts required and the amount of logistical and assembly work. This results in compact, ready-to-install ‘all-in-one’ electronic modules that require a minimum of space, thus reflecting the trend toward miniaturisation in electronics. On the other hand, at present the majority of these new applications must interface with traditional electronic components for functionality (eg. it’s not yet possible to print a microchip at present) and, moreover, many predict the UK will need to focus on R&D rather than mass-manufacturing. Incidentally, we’ve heard that a Russian state-backed company has invested GBP400m in Plastic Logic even though the company is planning its first high-volume, state-of-the-art manufacturing facility in… guess where? Dresden, Germany and not some remote Asian location!
The UK has a huge chance to groom R&D IP-drenched fledging indigenous companies to become the next advanced manufacturing global leaders, no matter if the high volume will be sited in bigger and/or cheaper countries. The key is to maintain the leading edge in R&D and design so that ultra-specialised and flexible manufacturing can still be performed in this country. A hybrid of plastic/printed electronics alongside surface mount technology (SMT) will most likely remain as the preferred methodology for the foreseeable future. However, it’s worth investigating the current problems facing many technology start-ups in the field and see whether there’s a market reality beyond speculation. One may conclude that plastic/printed electronics will be complementary to PCBs and the EMS industry rather than competitive but we all know how in technology (and electronics in particular) things change so quickly and the global market always rewards leaders, not followers.