David Savastano, Editor12.20.21
The automotive market is one of flexible and printed electronics’ strongest success stories. Printed electronics can be found in a variety of areas; printed heaters and sensors for seat belts and air bags have long been incorporated in our cars and trucks. BMW and Audi are using OLED tail lights in some of their models.
What is both interesting and promising are the new applications that are emerging. OLED displays for the interior of cars and trucks are providing designers with new tools to design with; Continental Corporation announced in November 2021 that is received a €1 billion order for its OLED displays. In-mold electronics are in the pipeline, changing the interior designs of cars while adding functionality. Carbon nanotube-based heaters in head lights and windshields have the potential to improve lighting and visibility.
Without a doubt, the automotive sector is going to continue to be one of the strongest markets for flexible and printed electronics.
Klaus Hecker, managing director of OE-A, noted a range of new applications, from curved displays in door-to-door dashboards, seamlessly integrating several OLED displays, touch functions and lighting to in-mold electronics touch surfaces.
“Printed area heating systems and battery balancing systems for electric vehicles are in the pipeline of many Tier 1 suppliers and OEMs,” Hecker added.
Dr. Matthew Dyson, senior technology analyst for IDTechEx, said that while adoption of new innovations is limited at present, there are lots of examples in qualification/development projects.
“It’s at least three years from product approval to commercialization,” Dr. Dyson noted. “One challenge is that once a technology is established, it’s rarely discussed, and not often identified as within the scope of ‘printed/flexible electronics’. Established applications of printed/flexible electronics in automotive include seat occupancy sensors, seat heaters (either resistive or PTC), and metal lines on rear windows for defogging.
“Applying functionalized films to the back of decorative thermoformed components to enable backlit capacitive touch has recently been commercialized by PolyIC (part of Kurz), and is definitely used in the recently release VW ID3 and Audi e-tron,” Dr. Dyson added. “Full IME that incorporates SMD components within the molded part (developed by TactoTek) has yet to be used in a commercially available car.”
Nick Morris, FHE technology manager at NextFlex, reported that automotive OEMs are becoming increasingly interested in adopting flexible hybrid and printed electronic technologies into their vehicles.
“Advancements in printing processes and flexible hybrid electronics (FHE) packaging techniques are enabling novel electronic architectures, seamlessly integrating functionality into automotive components not previously thought possible,” Morris said.
For example, Morris said that throughout the cabin, automakers want to incorporate smart surfaces with seamlessly integrated lighting, capacitive touch sensing, heating elements and occupant condition monitoring, while maintaining a soft and comfortable aesthetic.
“Improving the interaction between human and machines is a primary market where flexible electronics is a key enabling technology,” Morris noted. “Development of connected and autonomous vehicles is increasing demand for antennas and sensors integrated into vehicle exteriors. New materials and integration processes have emerged to allow for ever tighter integration of electronics sensing and processing into the structural features of the automotive body.
“Manufacturers are looking to utilize the benefits that printed electronics offer, including integrating transparent heating elements into windshields and interconnecting body panels with integrated antennas for communications and sensors, such as radar and lidar,” Morris noted. “As novel capabilities continue to be demonstrated by FHE and printed electronic component manufacturers, opportunities for adoption by the automotive industry continue to rise.”
OLED Technology in Cars and Trucks
Displays are an area of great interest to automotive OEMs and Tier 1s. Consumers are interested in new designs, and OLEDs are ideal for creativity. The announcement that Continental has received a €1 billion order for OLEDs is a clear signal that the technology is fast becoming mainstream.
“With the OLED technology in our multi-display solution, home movie enthusiasts now also have the full experience in cars. Our OLED display once again demonstrates that we are pioneers in the digital evolution of the cockpit,” said Dr. Frank Rabe, head of the Human Machine Interface business unit at Continental, in announcing the order. “The integrated OLED display ensures a first-class user experience and offers automotive manufacturers a further opportunity for differentiation and individualization.”
“The OLED display which we have announced is a multi-display that stretches from the driver’s area to the center console. It integrates two screens, which are optically bonded behind a curved glass surface,” noted Alena Liebram, external communications manager, Vehicle Networking and Information for Continental.
In-Mold Electronics
There is a lot of promise with in-mold-electronics for the automotive market. The ability to create lightweight, simpler devices with all of the functionality and much fewer parts has much appeal to automakers. Canatu, TactoTek, Novares and others are working on these systems.
One of the most interesting examples is the Origo Steering Wheel, developed by a Finnish automotive consortium including Canatu, TactoTek, Siili Auto and Rightware. Origo allows the driver to manage all of the car’s key functions from the steering wheel, which is a major benefit in terms of safety and cutting down distractions. It brings the smart device User Experience (UX) to cars and trucks. Origo has earned prestigious awards, including the 2021 German Design Award and, most recently, a CES 2022 Innovation Award.
Mari Makkonen, VP, marketing and communications for Canatu Oy, noted that Canatu brought its expertise in CNT 3D touch surfaces to the project. Makkonen added that Canatu shapes surfaces into experiences by bringing touch on any 3D shape and surface.
“Innovative 3D touch sensors replace multiple mechanical controls, enabling sleek, light and unobtrusive interiors. Transparency allows for customizable illuminated designs,” said Makkonen.
“Canatu 3D touch enables design freedom and intuitive UX. With 3D formed touch sensors, any surface can be smart and functional,” added Canatu Oy CTO Ilkka Vargos.
“Origo is a compelling example of how innovative design and manufacturing technologies, combined with leading-edge software, are enhancing user experiences,” added Jussi Harvela, TactoTek CEO, when the award was announced.
Clayens NP Group is a global leader in processing polymers, composites and precision metal parts. Clayens NP has key positions in major industries including automotive and aerospace, and is partnering with industry leaders such as TactoTek in the area of in-mold electronics (IME).
Dr. Didier Muller, material and smart plastic expert with Clayens NP Group, noted that Clayens has expertise in printing and ejection molding, which led to the company looking at in-mold electronics, printed electronics and smart plastics.
“We decided to go into smart plastics or plastronics more than 12 years ago, and also entered the fields of in-mold electronics and printed electronics six years ago as we have capabilities and knowledge in screenprinting and ejection molding,” Dr. Muller observed. “Today we are able to produce some parts for ourselves, and we are creating proof of concept right now.”
Dr. Muller pointed to numerous advantages that make in-mold electronics attractive to auto makers.
“Freedom of design is first, as eliminating rigid PCBs allows designers any kind of design and more space because there is no need for the PCB and a shell,” Dr. Muller said. “You can have more space to do other things. The second benefit is lightweighting, which is a great advantage with any transportation, and there are also advantages in technical parts as there is no need for extra parts.”
Dr. Muller highlighted a recent example of how IME can benefit auto makers.
“We had a request for a switchboard and the customer wanted to add new functionalities,” he noted. “With in-mold electronics, we could add new functionalities by putting the functionality into the wall itself. This gives customers new possibilities also. You can also add sensors wherever you need them and have them be more accurate.”
Dr. Muller noted that Clayens NP has relationships with customers in different markets, and they are reporting that IME looks promising.
“Tier 1s say it is coming tomorrow, and in-mold electronics are performing with a lot of hope,” said Dr. Muller. “COVID-19 did change the paradigm. When it will come I don’t know, perhaps within two or three years.
“The question is what is the real value for the customer – we have to fully change their minds,” Dr. Muller added. “Are smart electronics or smart plastics able to give answers or confidence – the smart plastic industry is not yet organized or visible. We have to create that. Where can we see smart plastics? Everywhere. Human machine interfaces (HMI) and technical parts – as soon as there is a need, it becomes a must for customers, and then flexible and printed electronics will be the answer.”
Transparent Heaters
A new idea that has a lot of promise, transparent heaters are being developed that can defog headlights as well as the windshield, which is critical to allowing ADAS (advanced driver-assistance systems) sensors to function in bad weather.
“CHASM Advanced Materials and Asahi Kasei have both developed transparent heaters, based on CNT coated silver nanowires and printed metal mesh respectively. These are targeted at headlight and sensor covers. Transparent heaters are needed in electric vehicles due to the lack of residual heat,” said Dr. Dyson.
Canatu is also active in the ADAS camera and LiDAR (light detection and ranging) technologies.
“Recently, our team has focused developing the Canatu ADAS heater technology enabling autonomous driving in any weather,” said Varjos. “These transparent film heaters are used for keeping safety-critical optical surfaces clear from moisture, fog, frost and snow to enable reliable ADAS system performance under all weather conditions.
“What sets the technology apart is that as a transparent thin-film heater, it provides even heating performance without interference with electronic signals,” Varjos added. “While metallic wire heaters can cause optical distortion and induce additional LiDAR beam deflection, the Canatu ADAS heaters offer clear visibility with maximum transmittance. Due to high flexibility, Canatu ADAS heater can be fabricated in any 3D shape, and on a variety of substrates, enabling easy integration by means of film injection moulding or lamination where needed, to ensure safe automated driving in any weather.”
Ken Klapproth, VP of marketing for CHASM, said that by using CHASM’s flexible and formable transparent conductive films, designers are free to implement new ADAS technologies or stylized new organically-shaped vehicle lighting knowing that transparent heat will keep them clear of inclement weather, keeping them continually available and passengers safe.
“Transparent antennas can be added to the untapped real-estate of vehicle glass, improving wireless signal connectivity,” added Klapproth. “At the same time, CHASM transparent conductive films offer Tier 1 and Tier 2 suppliers a cost effective and robust platform to manufacture these latest innovations for OEMs.”
Challenges Ahead
Even with the advantages that flexible and printed electronics offer, there are challenges that suppliers face in terms of getting their products into vehicles. OE-A’s Hecker pointed to long lead times, high standards on reliability, cost and the need to convince an established industry to adapt a new technology.
Among the biggest challenges that Dr. Wolfgang Clemens, director product management & business development and member of the Managing Board of PolyIC, sees are the long time from prototype to real product, pricing pressures and high quality demands, that need to be tested and adjusted before coming to market.
Morris said that one of the biggest challenges to adoption of these products is the current lack of automotive-specific design and manufacturing standards for flexible hybrid and printed electronics. Enabling this collaboration is one of the key reasons NextFlex launched its Automotive Technical Working Group.
“Manufacturing and reliability standards are critical for the automotive OEMs and their tier suppliers, and because of this, adoption of innovative technologies can be slow,” Morris said. “Proven high reliability of flexible and printed components is critical for development of standards and advancement will only happen when OEMs, component manufacturers, and technology developers collaborate and share knowledge about reliability requirements, manufacturing capabilities, and testing protocols.
Morris said that another challenge suppliers face for adoption is the need to further reduce component costs.
“Higher volume manufacturing processes are needed to meet the margin demands of the automotive industry,” said Morris. “Luxury brands will be the leader of adoption of these technologies, but a further increase in manufacturing volumes will lead to the reductions in costs.”
“Projects are long and some OEMs are risk averse when it comes to introducing new technology and -suppliers into vehicles,” Varjos observed.
“As usual with any new technology for automotive applications, the qualification requirements are quite rigorous and time consuming to complete,” Dr. Dyson added. “The printed/flexible electronics technology needs to withstand the 85/85 humidity/temperature test, vibrations and repeated thermal cycling. Ultimately cars are often kept outside and expected to last at least 10 years, so durability is essential. Even once technologies are qualified, the automotive development cycle is at least three years so it’s a while before they end up in cars available for sale.”
Klapproth noted that one of the challenges for an “ingredient company’ like CHASM is the multi-step qualification process faced for innovative new materials to the automotive industry.
“First, the material itself requires validation that it delivers the proposed technical benefits, followed by the validation that it can be cost-effectively manufactured at scale for the intended application with little disruption to the supply chain,” he added. “For example, a transparent heating film keeping the field of view for ADAS cameras clear must first demonstrate desired temperatures, time and power profiles, followed by integration into a windshield assembly.”
Recent Innovations and New Opportunities
There are a host of new innovations that have come out or are nearing commercialization.
“Louisenthal has developed an innovative method to produce transparent conductive films, with the main target application being automotive interior films,” said Dr. Dyson. “The transparent heater has been used in development projects by both Volkswagen and BMW. The basic approach is to apply a nanoparticle coating, then dry it at around 60°C. This results in cracking, similar to dry mud on a lake bed. The entire surface is then metallized (likely via spraying or sputtering). Finally, the nanoparticle coating is removed to leave a pattern of conductive lines that corresponds to the cracks.
Clemens pointed to a variety of new sensors, including steering wheel sensors for the VW ID-family, button sensors for Audi A3, Audi Q4/Etron, and BMW iX.
Arne Casteleyn, managing director – sales & strategy for Quad Industries, noted that Quad is working on capacitive touch films for HVAC and other controls and heating films both inside and outside of the vehicle. He said that the biggest challenge is cost, and noted that integration of printed heaters in interior parts is a recent innovation.
“There will be heated surfaces ‘everywhere’ to increase passenger comfort in electric vehicles, as well as in technical exterior parts such as fluid tanks and battery systems,” Castelyn noted.
“The most recent trend we’ve seen is the seamless integration of printed electronics into smart interior surfaces with lighting and capacitive touch for steering wheel and overhead console controls,” Morris said. “There are currently production vehicles with steering wheel and center console controls manufactured using printed and in-mold electronic processes, but soon these functionalities will be integrated into interior surfaces that have not typically featured these capabilities, such as within the seats, dashboards, door panels, and interior headliners. This demand is driving electronic integration into automotive interior materials such as leather, soft-touch plastics, and curved glass.”
Morris noted that further advancement of FHE and printed electronics manufacturing will continue to enable new opportunities and interest by auto manufacturers.
“Further opportunities include vehicle weight reduction and increased sustainability through printed alternatives to traditional metal-wire wiring harnesses for interconnection of the ever-increasing number of electronic components on a modern vehicle,” Morris said. “Additionally, as the market share of EVs continues to grow, there will be additional opportunities for these technologies as thin film sensors incorporated into the batteries themselves to continuously monitor cell health and useful operational life.”
“We see opportunities for flexible and printed sensors especially in the automotive ADAS heaters, touch sensors and medical diagnostics,” Varjos said.
“I think there’s a big long term opportunity for printed/flexible transparent heaters on automotive windows for defrosting/defogging,” Dr. Dyson said. “Unlike sensor covers or to some extent headlights, the area/volume involved is huge. The value proposition of never having to defrost windows again is also very compelling.
“Adding curved OLED displays to the interior would enable pillars to ‘become invisible’, improving driver visibility and the sense of spaciousness (even for autonomous vehicles),” Dr. Dyson observed. “There is lots of discussion at present around moving from ‘space heating’ (i.e., blowing hot air around) to heating surfaces within the cabin, and printed heaters are suited to this.
“In the longer term, there is scope for replacing wiring harnesses with electronics printed (or wire spooled) onto 3D surfaces prior to dielectric being printed over the top – Q5D Technologies is developing this,” added Dr. Dyson. “In the longer term, lightweight flexible PV could be used to supplement charging for EVs – potentially providing enough power per day for local journeys.”
“Consumer expectations continue to evolve with respect to the ease, simplicity, and intuitive operation for interacting with electronic devices,” said Klapproth. “Automotive vehicle interiors are increasingly leveraging in-mold electronics (IME) adding touch control to any 3D surface as desired. This enables interior designers and stylists to fundamentally rethink how passengers interact with their surroundings. For electric vehicles where every amp matters and vehicle operating range is still a top barrier to customer adoption, the ability to reimagine systems like cabin climate control – efficiently putting conditioned surfaces close to passengers rather than blowing air around the cabin – can deliver that ‘wow’ factor. Flexible and printed electronics have a strong role in helping to realize this future.”
What is both interesting and promising are the new applications that are emerging. OLED displays for the interior of cars and trucks are providing designers with new tools to design with; Continental Corporation announced in November 2021 that is received a €1 billion order for its OLED displays. In-mold electronics are in the pipeline, changing the interior designs of cars while adding functionality. Carbon nanotube-based heaters in head lights and windshields have the potential to improve lighting and visibility.
Without a doubt, the automotive sector is going to continue to be one of the strongest markets for flexible and printed electronics.
Klaus Hecker, managing director of OE-A, noted a range of new applications, from curved displays in door-to-door dashboards, seamlessly integrating several OLED displays, touch functions and lighting to in-mold electronics touch surfaces.
“Printed area heating systems and battery balancing systems for electric vehicles are in the pipeline of many Tier 1 suppliers and OEMs,” Hecker added.
Dr. Matthew Dyson, senior technology analyst for IDTechEx, said that while adoption of new innovations is limited at present, there are lots of examples in qualification/development projects.
“It’s at least three years from product approval to commercialization,” Dr. Dyson noted. “One challenge is that once a technology is established, it’s rarely discussed, and not often identified as within the scope of ‘printed/flexible electronics’. Established applications of printed/flexible electronics in automotive include seat occupancy sensors, seat heaters (either resistive or PTC), and metal lines on rear windows for defogging.
“Applying functionalized films to the back of decorative thermoformed components to enable backlit capacitive touch has recently been commercialized by PolyIC (part of Kurz), and is definitely used in the recently release VW ID3 and Audi e-tron,” Dr. Dyson added. “Full IME that incorporates SMD components within the molded part (developed by TactoTek) has yet to be used in a commercially available car.”
Nick Morris, FHE technology manager at NextFlex, reported that automotive OEMs are becoming increasingly interested in adopting flexible hybrid and printed electronic technologies into their vehicles.
“Advancements in printing processes and flexible hybrid electronics (FHE) packaging techniques are enabling novel electronic architectures, seamlessly integrating functionality into automotive components not previously thought possible,” Morris said.
For example, Morris said that throughout the cabin, automakers want to incorporate smart surfaces with seamlessly integrated lighting, capacitive touch sensing, heating elements and occupant condition monitoring, while maintaining a soft and comfortable aesthetic.
“Improving the interaction between human and machines is a primary market where flexible electronics is a key enabling technology,” Morris noted. “Development of connected and autonomous vehicles is increasing demand for antennas and sensors integrated into vehicle exteriors. New materials and integration processes have emerged to allow for ever tighter integration of electronics sensing and processing into the structural features of the automotive body.
“Manufacturers are looking to utilize the benefits that printed electronics offer, including integrating transparent heating elements into windshields and interconnecting body panels with integrated antennas for communications and sensors, such as radar and lidar,” Morris noted. “As novel capabilities continue to be demonstrated by FHE and printed electronic component manufacturers, opportunities for adoption by the automotive industry continue to rise.”
OLED Technology in Cars and Trucks
Displays are an area of great interest to automotive OEMs and Tier 1s. Consumers are interested in new designs, and OLEDs are ideal for creativity. The announcement that Continental has received a €1 billion order for OLEDs is a clear signal that the technology is fast becoming mainstream.
“With the OLED technology in our multi-display solution, home movie enthusiasts now also have the full experience in cars. Our OLED display once again demonstrates that we are pioneers in the digital evolution of the cockpit,” said Dr. Frank Rabe, head of the Human Machine Interface business unit at Continental, in announcing the order. “The integrated OLED display ensures a first-class user experience and offers automotive manufacturers a further opportunity for differentiation and individualization.”
“The OLED display which we have announced is a multi-display that stretches from the driver’s area to the center console. It integrates two screens, which are optically bonded behind a curved glass surface,” noted Alena Liebram, external communications manager, Vehicle Networking and Information for Continental.
In-Mold Electronics
There is a lot of promise with in-mold-electronics for the automotive market. The ability to create lightweight, simpler devices with all of the functionality and much fewer parts has much appeal to automakers. Canatu, TactoTek, Novares and others are working on these systems.
One of the most interesting examples is the Origo Steering Wheel, developed by a Finnish automotive consortium including Canatu, TactoTek, Siili Auto and Rightware. Origo allows the driver to manage all of the car’s key functions from the steering wheel, which is a major benefit in terms of safety and cutting down distractions. It brings the smart device User Experience (UX) to cars and trucks. Origo has earned prestigious awards, including the 2021 German Design Award and, most recently, a CES 2022 Innovation Award.
Mari Makkonen, VP, marketing and communications for Canatu Oy, noted that Canatu brought its expertise in CNT 3D touch surfaces to the project. Makkonen added that Canatu shapes surfaces into experiences by bringing touch on any 3D shape and surface.
“Innovative 3D touch sensors replace multiple mechanical controls, enabling sleek, light and unobtrusive interiors. Transparency allows for customizable illuminated designs,” said Makkonen.
“Canatu 3D touch enables design freedom and intuitive UX. With 3D formed touch sensors, any surface can be smart and functional,” added Canatu Oy CTO Ilkka Vargos.
“Origo is a compelling example of how innovative design and manufacturing technologies, combined with leading-edge software, are enhancing user experiences,” added Jussi Harvela, TactoTek CEO, when the award was announced.
Clayens NP Group is a global leader in processing polymers, composites and precision metal parts. Clayens NP has key positions in major industries including automotive and aerospace, and is partnering with industry leaders such as TactoTek in the area of in-mold electronics (IME).
Dr. Didier Muller, material and smart plastic expert with Clayens NP Group, noted that Clayens has expertise in printing and ejection molding, which led to the company looking at in-mold electronics, printed electronics and smart plastics.
“We decided to go into smart plastics or plastronics more than 12 years ago, and also entered the fields of in-mold electronics and printed electronics six years ago as we have capabilities and knowledge in screenprinting and ejection molding,” Dr. Muller observed. “Today we are able to produce some parts for ourselves, and we are creating proof of concept right now.”
Dr. Muller pointed to numerous advantages that make in-mold electronics attractive to auto makers.
“Freedom of design is first, as eliminating rigid PCBs allows designers any kind of design and more space because there is no need for the PCB and a shell,” Dr. Muller said. “You can have more space to do other things. The second benefit is lightweighting, which is a great advantage with any transportation, and there are also advantages in technical parts as there is no need for extra parts.”
Dr. Muller highlighted a recent example of how IME can benefit auto makers.
“We had a request for a switchboard and the customer wanted to add new functionalities,” he noted. “With in-mold electronics, we could add new functionalities by putting the functionality into the wall itself. This gives customers new possibilities also. You can also add sensors wherever you need them and have them be more accurate.”
Dr. Muller noted that Clayens NP has relationships with customers in different markets, and they are reporting that IME looks promising.
“Tier 1s say it is coming tomorrow, and in-mold electronics are performing with a lot of hope,” said Dr. Muller. “COVID-19 did change the paradigm. When it will come I don’t know, perhaps within two or three years.
“The question is what is the real value for the customer – we have to fully change their minds,” Dr. Muller added. “Are smart electronics or smart plastics able to give answers or confidence – the smart plastic industry is not yet organized or visible. We have to create that. Where can we see smart plastics? Everywhere. Human machine interfaces (HMI) and technical parts – as soon as there is a need, it becomes a must for customers, and then flexible and printed electronics will be the answer.”
Transparent Heaters
A new idea that has a lot of promise, transparent heaters are being developed that can defog headlights as well as the windshield, which is critical to allowing ADAS (advanced driver-assistance systems) sensors to function in bad weather.
“CHASM Advanced Materials and Asahi Kasei have both developed transparent heaters, based on CNT coated silver nanowires and printed metal mesh respectively. These are targeted at headlight and sensor covers. Transparent heaters are needed in electric vehicles due to the lack of residual heat,” said Dr. Dyson.
Canatu is also active in the ADAS camera and LiDAR (light detection and ranging) technologies.
“Recently, our team has focused developing the Canatu ADAS heater technology enabling autonomous driving in any weather,” said Varjos. “These transparent film heaters are used for keeping safety-critical optical surfaces clear from moisture, fog, frost and snow to enable reliable ADAS system performance under all weather conditions.
“What sets the technology apart is that as a transparent thin-film heater, it provides even heating performance without interference with electronic signals,” Varjos added. “While metallic wire heaters can cause optical distortion and induce additional LiDAR beam deflection, the Canatu ADAS heaters offer clear visibility with maximum transmittance. Due to high flexibility, Canatu ADAS heater can be fabricated in any 3D shape, and on a variety of substrates, enabling easy integration by means of film injection moulding or lamination where needed, to ensure safe automated driving in any weather.”
Ken Klapproth, VP of marketing for CHASM, said that by using CHASM’s flexible and formable transparent conductive films, designers are free to implement new ADAS technologies or stylized new organically-shaped vehicle lighting knowing that transparent heat will keep them clear of inclement weather, keeping them continually available and passengers safe.
“Transparent antennas can be added to the untapped real-estate of vehicle glass, improving wireless signal connectivity,” added Klapproth. “At the same time, CHASM transparent conductive films offer Tier 1 and Tier 2 suppliers a cost effective and robust platform to manufacture these latest innovations for OEMs.”
Challenges Ahead
Even with the advantages that flexible and printed electronics offer, there are challenges that suppliers face in terms of getting their products into vehicles. OE-A’s Hecker pointed to long lead times, high standards on reliability, cost and the need to convince an established industry to adapt a new technology.
Among the biggest challenges that Dr. Wolfgang Clemens, director product management & business development and member of the Managing Board of PolyIC, sees are the long time from prototype to real product, pricing pressures and high quality demands, that need to be tested and adjusted before coming to market.
Morris said that one of the biggest challenges to adoption of these products is the current lack of automotive-specific design and manufacturing standards for flexible hybrid and printed electronics. Enabling this collaboration is one of the key reasons NextFlex launched its Automotive Technical Working Group.
“Manufacturing and reliability standards are critical for the automotive OEMs and their tier suppliers, and because of this, adoption of innovative technologies can be slow,” Morris said. “Proven high reliability of flexible and printed components is critical for development of standards and advancement will only happen when OEMs, component manufacturers, and technology developers collaborate and share knowledge about reliability requirements, manufacturing capabilities, and testing protocols.
Morris said that another challenge suppliers face for adoption is the need to further reduce component costs.
“Higher volume manufacturing processes are needed to meet the margin demands of the automotive industry,” said Morris. “Luxury brands will be the leader of adoption of these technologies, but a further increase in manufacturing volumes will lead to the reductions in costs.”
“Projects are long and some OEMs are risk averse when it comes to introducing new technology and -suppliers into vehicles,” Varjos observed.
“As usual with any new technology for automotive applications, the qualification requirements are quite rigorous and time consuming to complete,” Dr. Dyson added. “The printed/flexible electronics technology needs to withstand the 85/85 humidity/temperature test, vibrations and repeated thermal cycling. Ultimately cars are often kept outside and expected to last at least 10 years, so durability is essential. Even once technologies are qualified, the automotive development cycle is at least three years so it’s a while before they end up in cars available for sale.”
Klapproth noted that one of the challenges for an “ingredient company’ like CHASM is the multi-step qualification process faced for innovative new materials to the automotive industry.
“First, the material itself requires validation that it delivers the proposed technical benefits, followed by the validation that it can be cost-effectively manufactured at scale for the intended application with little disruption to the supply chain,” he added. “For example, a transparent heating film keeping the field of view for ADAS cameras clear must first demonstrate desired temperatures, time and power profiles, followed by integration into a windshield assembly.”
Recent Innovations and New Opportunities
There are a host of new innovations that have come out or are nearing commercialization.
“Louisenthal has developed an innovative method to produce transparent conductive films, with the main target application being automotive interior films,” said Dr. Dyson. “The transparent heater has been used in development projects by both Volkswagen and BMW. The basic approach is to apply a nanoparticle coating, then dry it at around 60°C. This results in cracking, similar to dry mud on a lake bed. The entire surface is then metallized (likely via spraying or sputtering). Finally, the nanoparticle coating is removed to leave a pattern of conductive lines that corresponds to the cracks.
Clemens pointed to a variety of new sensors, including steering wheel sensors for the VW ID-family, button sensors for Audi A3, Audi Q4/Etron, and BMW iX.
Arne Casteleyn, managing director – sales & strategy for Quad Industries, noted that Quad is working on capacitive touch films for HVAC and other controls and heating films both inside and outside of the vehicle. He said that the biggest challenge is cost, and noted that integration of printed heaters in interior parts is a recent innovation.
“There will be heated surfaces ‘everywhere’ to increase passenger comfort in electric vehicles, as well as in technical exterior parts such as fluid tanks and battery systems,” Castelyn noted.
“The most recent trend we’ve seen is the seamless integration of printed electronics into smart interior surfaces with lighting and capacitive touch for steering wheel and overhead console controls,” Morris said. “There are currently production vehicles with steering wheel and center console controls manufactured using printed and in-mold electronic processes, but soon these functionalities will be integrated into interior surfaces that have not typically featured these capabilities, such as within the seats, dashboards, door panels, and interior headliners. This demand is driving electronic integration into automotive interior materials such as leather, soft-touch plastics, and curved glass.”
Morris noted that further advancement of FHE and printed electronics manufacturing will continue to enable new opportunities and interest by auto manufacturers.
“Further opportunities include vehicle weight reduction and increased sustainability through printed alternatives to traditional metal-wire wiring harnesses for interconnection of the ever-increasing number of electronic components on a modern vehicle,” Morris said. “Additionally, as the market share of EVs continues to grow, there will be additional opportunities for these technologies as thin film sensors incorporated into the batteries themselves to continuously monitor cell health and useful operational life.”
“We see opportunities for flexible and printed sensors especially in the automotive ADAS heaters, touch sensors and medical diagnostics,” Varjos said.
“I think there’s a big long term opportunity for printed/flexible transparent heaters on automotive windows for defrosting/defogging,” Dr. Dyson said. “Unlike sensor covers or to some extent headlights, the area/volume involved is huge. The value proposition of never having to defrost windows again is also very compelling.
“Adding curved OLED displays to the interior would enable pillars to ‘become invisible’, improving driver visibility and the sense of spaciousness (even for autonomous vehicles),” Dr. Dyson observed. “There is lots of discussion at present around moving from ‘space heating’ (i.e., blowing hot air around) to heating surfaces within the cabin, and printed heaters are suited to this.
“In the longer term, there is scope for replacing wiring harnesses with electronics printed (or wire spooled) onto 3D surfaces prior to dielectric being printed over the top – Q5D Technologies is developing this,” added Dr. Dyson. “In the longer term, lightweight flexible PV could be used to supplement charging for EVs – potentially providing enough power per day for local journeys.”
“Consumer expectations continue to evolve with respect to the ease, simplicity, and intuitive operation for interacting with electronic devices,” said Klapproth. “Automotive vehicle interiors are increasingly leveraging in-mold electronics (IME) adding touch control to any 3D surface as desired. This enables interior designers and stylists to fundamentally rethink how passengers interact with their surroundings. For electric vehicles where every amp matters and vehicle operating range is still a top barrier to customer adoption, the ability to reimagine systems like cabin climate control – efficiently putting conditioned surfaces close to passengers rather than blowing air around the cabin – can deliver that ‘wow’ factor. Flexible and printed electronics have a strong role in helping to realize this future.”
