Printed electronics (PE) entrepreneurs are continuously developing new products in their labs. Once the concept is proved, the challenge then becomes moving the product into small-scale production.

PragmatIC Printing Ltd., a specialist in imprinted logic circuits, has reached the point of bringing its products to pilot-stage production. Having acquired the PE business of Nano ePrint Ltd. in 2010, PragmatIC has made headway in a number of areas in recent months.

PragmatIC's pilot line will utilize CPI's state-of-the-art facilities.

In November 2011, PragmatIC, in conjunction with Innovia Films Ltd., announced the successful integration of printed electronic functionality onto Innovia Films’ biaxially oriented polypropylene (BOPP) label substrates. The first prototypes are interactive bottle labels that activate a sequence of flashing lights when the bottle is held.

In September, 2011, PragmatIC and De La Rue plc, the world’s largest integrated commercial security printer and papermaker, announced progress in prototyping extremely flexible and thin printed electronic security products. Power would be harvested wirelessly from a standard RFID or NFC reader . In July 2011, PragmatIC announced the completion of prototype printed electronic greeting cards for Tigerprint Ltd., a Hallmark subsidiary.

In order to make the next step, PragmatIC has announced plans to move its technology to pilot-scale production under an agreement with The Centre for Process Innovation (CPI), a UK -based technology innovation center and part of the “High Value Manufacturing Catapult” – a UK initiative to speed up commercialization of key technologies.

In addition to supporting commercial production for low volume applications, the pilot line also provides a platform for the collaborative PragmatIC Pilot Production Program (P4).

Scott White, PragmatIC Printing Limited’s CEO, said that PragmatIC’s business model is focused on licensing its technology in markets ranging from consumer goods (brand promotion, smart packaging ); security products (brand protection, document/identity authentication ); and novelties (greeting cards, toys, games). In the longer term, White added that there are further opportunities in sensors, control systems and mobile devices.

White said that having access to a state-of-the-art pilot production line is a huge advantage for PragmatIC.

“Although our core business model is licensing of our technology, our ongoing engagement with end users and other commercial partners has shown that there is a strong business case for a long term pilot-scale production facility,” White said. “This will help us support our licensees with further process development, as well as providing low volume capacity for commercial use of our imprinted logic by system integrators and end users.”

Once the decision was reached to begin pilot production, White said that CPI was the clear choice.

“CPI's extensive investment in state-of-the-art facilities relevant to printed electronics makes them an ideal partner, both for the equipment needed in our own pilot line, as well as complementary activities such as the Integrated Smart Systems line,” White noted.

CPI brings a number of key benefits to the PragmatIC project. First off, the extensive range of equipment is excellent enables rapid establishment of a baseline process as well as supporting ongoing process enhancement.

“CPI has developed a flexible toolset that enables companies like PragmatIC to ‘de-risk’ their commercialization process by providing them with access to state-of-the-art scalable equipment and highly skilled technical support,” said Matthew Herbert, CPI’s marketing manager. “The equipment set at CPI has been chosen deliberately to give users a good indication of the performance of their materials and processes at manufacturing scale.”

CPI also brings a wealth of experience in electronics and semiconductors.

“Most of the team members have come from the semiconductor and electronics industries and are able to give good advice on the best way of achieving a user’s aims on the equipment set,” Herbert noted. “In addition, the flexible support models established at CPI allow users to use the equipment themselves (under guidance from CPI personnel), or use CPI staff to carry out the work. CPI will support a company in a way that makes sense for them.”

PragmatIC  will be utilizing CPI’s Integrated Smart Systems, a new line being installed at CPI that will allow electronic functionality to be combined with conventional printing.

“There are a number of printing techniques in regular use in the print industry, so CPI has specified a print line that is capable of supporting a number of different printing techniques (rotary screen, offset lithography , flexography and gravure ) using a modular press,” Herbert said. “This press line can print conductive tracks and a range of passive devices such as switches and resistors.”

Herbert noted that the ISS equipment also includes a “pick and place” machine that will allow small, conventional electronic components to be combined with the printed conductors .

“This means that devices such as greetings cards with LEDs and packaging with functionality can be produced,” Herbert said. “The line also includes a cut and crease machine, allowing the printed substrates to be converted into, say, functional packaging.

“PragmatIC is producing a range of imprinted logic devices that will be a perfect match with the capability of this line, allowing demonstrators with a continual progression of exciting functionality to be produced,” Herbert added. “CPI will allow PragmatIC to demonstrate the full power of their products with a range of demonstrators, all potentially capable of volume production.”

Herbert sees numerous areas where PragmatIC’s technology can benefit brand owners and end-users alike.

“PragmatIC’s technology will be very useful in developing a wide range of printed, electronically functional products,” Herbert said. “Brand protection and security (e.g. event tickets) are obvious applications, but there are potential applications in the medical field with point of care diagnosis and printed sensors. PragmatIC gives the world of Integrated Smart Systems a new range of options when it comes to developing functional products. The ISS sector of the market is certainly the closest to commercialization, so this is a very exciting field.”

With the collaboration with CPI in place, White sees excellent opportunities for further partnerships, which will ultimately benefit the entire PE ecosystem.

“We obviously see significant growth for PragmatIC, but the objective of our ‘P4’ initiative is to ensure a complementary ecosystem for other printed electronics technologies and the integration of these into customer- led products,” White concluded. “We feel that with this approach, enough pieces of the puzzle are in place for things to take off quite rapidly.”