<html><head></head><body><p>There is a rising demand for smaller, thinner, and stretchable electronics to bring the innovations of tomorrow to life. In response, electronics manufacturing is adapting to meet these new requirements across industries. Flexible hybrid electronics (FHE), in particular, are notable for their capacity to bend and stretch without compromising the integrity of the electronic circuits, while enabling rapid prototyping.</p><h2 id="isPasted">What are flexible hybrid electronics?</h2><p>Flexible hybrid electronics combine the best of printed and traditional electronics to create electronics that can bend, stretch, and conform to their environment. They are characterized by the combination of printed, conductive interconnects, flexible or stretchable substrates, and mounted components. This allows for devices that are not only lightweight and flexible, but also highly functional, enabling <a href="https://www.voltera.io/applications">new applications</a> in fields such as healthcare, consumer electronics, automotive, and beyond.</p><p>Printable and flexible hybrid electronics open new doors for industries that require flexible, biocompatible, conformable, and stretchable devices. With advancements in materials and manufacturing processes, FHE offers a tremendous impact for <a href="https://www.voltera.io/use-cases/industries">industries</a> creating wearable devices, flexible displays, and even implantable electronics that can stretch with the body or adapt to irregular surfaces, among many others.</p><h2>Key components of flexible hybrid electronics</h2><p>The combination of flexible materials and rigid components makes flexible hybrid electronics unique from printed electronics or traditional rigid PCBs. FHEs integrate the advantages of flexible substrates with the robustness of conventional rigid electronic components and integrated circuits (IC), allowing researchers and engineers to customize electronics for their research, applications, and products.</p><h3>Substrates for FHEs</h3><p id="isPasted">What makes FHEs unique from other types of electronics is their use of substrates that are flexible and stretchable. <a href="https://store.voltera.io/products/pet-5-sheets?_pos=6&amp;_fid=65f88ddf8&amp;_ss=c">Polyethylene terephthalate (PET)</a> is commonly used for FHEs because it is cost-effective, durable, and flexible. However, <a href="https://store.voltera.io/products/intexar-tpu-5-sheets?_pos=7&amp;_fid=65f88ddf8&amp;_ss=c">thermoplastic polyurethane (TPU)</a>, <a href="https://store.voltera.io/products/polyimide-5-sheets?_pos=8&amp;_fid=65f88ddf8&amp;_ss=c">polyimide (PI)</a>, <a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials/lineup/beyolex-stretchable-circuit-materials" target="_blank">BEYOLEX</a>, and even novel substrates can offer different advantages, like biocompatibility or increased stretchability.&nbsp;</p><p>Some common substrate suppliers include (but are not limited to):</p><ul><li><a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials" target="_blank">Panasonic</a></li><li><a href="https://normandy-coating.com/en/" target="_blank">Normandy Coating</a></li><li><a href="https://www.dupont.com/electronics-industrial/printed-circuit-boards.html" target="_blank">Dupont</a></li><li><a href="https://polyonics.com/Resources/about-our-products.php#" target="_blank">Polyonics</a></li></ul><h3 id="isPasted">Conductors and interconnects for FHEs</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788721796-67575c5215dd04c49acc860c_67575b0cbddec4287e182d8d_printing-conductive-copper-ink-flexible-hybrid-electronics.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper" id="isPasted">Printing copper ink</a></span></span></span></p><p id="isPasted">Conductive inks are printed on flexible substrates to create electrical connections between components in FHEs. These inks are often flexible and/or stretchable to maintain conductivity, even when the substrate is bent, twisted, or stretched. Ink is printed via printing processes such as direct ink writing, <a href="https://www.voltera.io/blog/introduction-inkjet-technology?srsltid=AfmBOooLgmtxfhJnJcFE6HwnMhtaAIAZc-sEWeeArH1babbH5SFoRI7f">inkjet printing</a>, and aerosol printing. <a href="https://www.voltera.io/blog/screen-printing-direct-ink-writing-printed-electronics">Direct ink writing</a>, in particular, ensures that ink is only applied where it is needed which eliminates unnecessary material waste.&nbsp;</p><p>Some common ink suppliers for FHE include (but are not limited to):</p><ul><li><a href="https://www.acimaterials.com/products/" target="_blank">ACI Materials&nbsp;</a></li><li><a href="https://www.celanese.com/" target="_blank">Celanese</a></li><li><a href="https://www.copprint.com/products/" target="_blank">Copprint</a></li><li><a href="https://www.creativematerials.com/products" target="_blank">Creative Materials</a></li><li><a href="https://www.elantas.com/europe/products/printed-electronics/products.html" target="_blank">Elantas</a></li><li><a href="https://www.henkel-adhesives.com/ca/en/products/industrial-coatings/inks-coatings.html" target="_blank">Henkel</a></li><li><a href="https://www.heraeus-group.com/en/heraeus-businesses/#electronics" target="_blank">Heraeus</a></li><li><a href="https://novacentrix.com/" target="_blank">Novacentrix</a></li><li><a href="https://vfp-ink-technologies.com/functionnal-decorative-inks-varnishes/" target="_blank">VFP</a></li></ul><h3>Components for FHEs</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788785128-67575c5215dd04c49acc8655_675759a4c441da78918b7d60_flexible-hybrid-electronics-printed-pcb.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="isPasted">Flexible printed circuit</a></span></span></span></p><p id="isPasted">Flexible hybrid electronics use traditional components such as silicon chips or resistors. Thinned silicon dies are often used in FHEs to make circuits smaller, lighter, and more adaptable to flexible applications. Components are mounted onto the printed conductive paths, forming the <a href="https://www.idtechex.com/en/research-article/flexible-hybrid-electronics-future-of-flexible-printed-circuit-boards/20603" target="_blank">hybrid nature of FHEs</a>. Components are often coated with an encapsulant like epoxy resins, silicone, or polyimide to protect against corrosion and contaminants, and help to reinforce components on the substrate when flexed.</p><h2>Flexible hybrid electronics vs printed electronics vs flexible printed circuit boards</h2><p>Other types of electronics are similar to flexible hybrid electronics, so you might be wondering, how do flexible hybrid electronics compare to printed electronics (PE) and <a href="https://www.voltera.io/use-cases/applications/flexible-pcbs">flexible printed circuit boards</a> (FPCB)? Each type is uniquely positioned to tackle different electronics applications, so understanding the differences is key to choosing the right solution for different projects.&nbsp;</p><h3>Comparison of FHE vs PE vs FPCB</h3><table><thead><tr><th>Flexible hybrid electronics (FHE)</th><th>Printed electronics (PE)</th><th>Flexible printed circuit boards (FPCB)</th></tr></thead><tbody><tr><td>Flexible/stretchable substrate</td><td>Flexible/stretchable substrate</td><td>Flexible (usually polyimide) substrate</td></tr><tr><td>Conductive ink (printed)</td><td>Conductive ink (printed)</td><td>Etched copper or laminated foil interconnects</td></tr><tr><td>Rigid components</td><td>Printed components</td><td>Rigid components</td></tr><tr><td>Limitation: Mechanical stress could cause material fatigue or dislodge components over time</td><td>Limitation: Still many years out from mass manufacturing fully printed electronics</td><td>Limitation: Requires subtractive manufacturing to create conductive traces, which wastes material and causes excess pollution</td></tr><tr><td>Advantage: Thinner and more flexible than traditional PCBs, low-cost for small production runs</td><td>Advantage: All elements are thin, flexible, and/or stretchable</td><td>Advantage: Utilizes existing PCB manufacturing lines for higher-value devices</td></tr></tbody></table><h2>Future outlook for flexible hybrid electronics</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741788871734-67575c5215dd04c49acc8696_67575b836033c6402dc43a27_gold-ecg-electrode-bioelectronics-future.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="isPasted">Printed ECG electrode</a></span></span></span></p><p id="isPasted">Technological innovations are continually shaping the way industries approach electronics, and as a result, there is a growing demand for FHEs. According to<a href="https://www.idtechex.com/en/research-report/flexible-hybrid-electronics-2024-2034/950" target="_blank">&nbsp;IDTechEx</a>, the flexible hybrid electronics market is projected to reach $1.8 billion USD by 2034.&nbsp;</p><p>The main industries positioned for growth in the flexible hybrid electronics market are:</p><ul><li><a href="https://www.voltera.io/applications/bioelectronics">Bioelectronics</a>: FHEs enable flexible, biocompatible devices like biosensors, electrodes, and wearable health monitors, improving personalized medicine and real-time patient care.</li><li><a href="https://www.voltera.io/applications/wearables">Wearables</a>: FHEs make smart devices, fitness trackers, and e-textiles lighter, more comfortable, and more durable.</li><li><a href="https://www.voltera.io/applications/printed-batteries">Printed batteries</a>: FHEs support the development of lightweight, flexible printed batteries, creating energy storage solutions ideal for small, portable, and wearable devices.</li><li><a href="https://www.voltera.io/applications/printed-antennas">Antennas</a>: FHE-based antennas enable high-performance, bendable communication systems for 5G, IoT devices, and compact wearables.</li></ul><p>By merging the best features of printed electronics and traditional electronics, FHEs offer the versatility to meet the growing demand for smaller, thinner, and more flexible devices without compromising on performance or reliability. FHE technologies will drive the next wave of electronics, offering solutions that are functional, comfortable, and integrated seamlessly into everyday life.</p><p>Take a look at some of Voltera's in-house FHE projects:</p><ul><li><a href="https://www.voltera.io/application-whitepapers/printing-electroluminescent-ink-paper-pet">Printing Electroluminescent Ink on Paper and PET</a></li><li><a href="https://www.voltera.io/application-whitepapers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet">Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET</a></li></ul><p>Want the latest news in printed electronics? <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a?__hstc=13863464.78a9a3421439726983598cbbe37f8a6e.1724398561694.1739442788711.1741782731386.30&amp;__hssc=13863464.1.1741782731386&amp;__hsfp=2596353879" target="_blank" rel="noopener noreferrer">Subscribe to Voltera's newsletter</a>. If you have questions about your PCB printing needs, you can get in touch with Voltera at <a href="mailto:sales@voltera.io">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting">book a meeting</a>.</p></body></html>

Flexible hybrid electronics (FHE) enable bendable, stretchable devices for healthcare, consumer tech, and automotive. Explore how electronics manufacturers are leveraging FHE to meet new requirements across industries.

What are Flexible Hybrid Electronics (FHE)?

<p dir="ltr" id="isPasted">In recent years, the process for developing electronics has transformed significantly due to the rise in electronic printing technologies. Compared to more conventional electronic production methods like physical vapor deposition (PVD) and etching, additive printing technologies such as direct ink writing (DIW) have ushered in a more agile and cost-effective way to design and prototype cutting-edge electronic devices, including flexible electronics and biosensors.&nbsp;</p><p dir="ltr">Not only that, advanced printing hardware, like <a href="https://www.voltera.io/nova?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=nova">Voltera’s NOVA materials dispensing system</a>, is unlocking unprecedented capabilities in terms of complex and highly intricate circuits, which offer enhanced functionality without significantly increasing the cost or complexity of the production process. These benefits are in large part thanks to <a href="https://www.voltera.io/blog/precision-fluid-dispensing-systems?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=precision-fluid-dispensing">precision fluid dispensing</a>, a system that facilitates the controlled deposition of conductive inks in micro amounts onto a substrate.</p><p dir="ltr" id="isPasted">In this article, we will explore how closed-loop precision fluid dispensing systems, such as the Smart Dispenser integrated in Voltera’s NOVA platform, are playing a central role in the development of advanced electronics and are opening up greater material possibilities for future electronic devices.</p><h2 dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/erRY7sHCaP8?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></h2><h2 dir="ltr">Smart Dispenser: unlocking precision with closed-loop control</h2><p dir="ltr">Voltera’s NOVA is a modular materials dispensing platform capable of printing a wide range of functional materials (conductive, dielectric, adhesives, luminescent) onto an equally diverse array of substrates, from rigid PCBs to flexible materials like PET, TPU, polymers, and paper. The system, used for the rapid development and prototyping of electronic devices, requires no tooling and minimizes material waste, resulting in 90% faster iteration times and 96% reduced material costs.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741079918299-NOVA+printing+a+stretchable+dielectric+ink.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA printing a stretchable dielectric ink.</span></span></span></p><p dir="ltr" id="isPasted">One of the key technologies behind NOVA’s versatility and precision is the Smart Dispenser, a self-contained dispensing module for ink and paste materials. In short, it is the Smart Dispenser that makes it possible to create high-resolution traces using virtually any screen printable ink (from 1,000 to 1,000,000 cps).&nbsp;</p><p dir="ltr">Depending on the viscosity of the ink used, the Smart Dispenser is able to print traces down to 100 μm in width with incredible consistency thanks to a closed-loop pressure feedback system. This system relies on an advanced pressure sensor, which monitors both the dispensing pressure and ink flow rate, as well as a new dispensing algorithm and automatic fluid level detection.&nbsp;</p><p dir="ltr">In addition to the Smart Dispenser’s closed-loop pressure feedback, the dispensing module integrates a heater, which enables users to control the temperature of the printing material. Maintaining an optimal temperature throughout the printing process is key to ensuring a stable material viscosity, which in turn results in more consistent trace widths.&nbsp;</p><p dir="ltr">Voltera has found that a temperature of 35°C (95°F) is ideal, striking a balance between keeping a stable material temperature—even with ambient temperature fluctuations and passive heating from the system’s electronics—and maintaining the ink’s properties, which could be affected by a higher temperature.[1] Other knock-on benefits of the dispenser’s heating function include minimized leakage (as a result of creating a negative pressure inside the material cartridge) and faster printing since cartridges do not need to be re-pressurized throughout the printing process. &nbsp;</p><p dir="ltr">Overall, NOVA’s Smart Dispenser and its closed-loop pressure feedback give users the ability to confidently work with a wide range of conductive inks and pastes while benefiting from rapid printing speeds and consistent print quality. From a user’s perspective, the Smart Dispenser is also adaptable, allowing for rapid material changes for multi-material prints, and can be used with various precision dispensing tips (like Nordson EFD 5CC syringe barrels and other standard Luer lock nozzles).&nbsp;</p><h2 dir="ltr" id="isPasted">Integrating the NOVA into an electronics prototyping workflow</h2><p dir="ltr">Just as users can easily swap material cartridges in the Smart Dispenser module, the entire NOVA platform is designed for ease of use. Intended for materials testing and flexible hybrid electronics R&amp;D, rapid prototyping, and small-volume production, Voltera’s NOVA dispensing platform is remarkably simple to install, enabling users to start printing shortly after unboxing and seamlessly transform their materials and electronics development workflow.</p><p dir="ltr">Setting up NOVA only takes minutes. Simply unbox NOVA’s components, connect it to power and Wi-Fi via the included USB dongle, and then log into the browser-based interface to finish the guided set-up process.[2] Additionally, NOVA can also be used in offline mode for those wanting to protect their IP.</p><p dir="ltr">Initiating the printing process is equally seamless thanks to a semi-automated calibration procedure and simple material loading with the Smart Dispenser. NOVA’s calibration process also includes test patterns, which users can check and approve remotely before the printing begins. To adjust print settings, users simply have to indicate what needs improvement (i.e. more or less pressure is needed, or changing when pressure is increased or decreased along trace starts and stops) and NOVA’s software will automatically apply the new settings. Once the user is satisfied with the calibration test, the real printing can begin. With NOVA, you only need to calibrate yourtheir materials once as it allows you to save the material profile for future use.</p><p dir="ltr">A new software feature, <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova?utm_campaign=Wevolver&utm_source=website&utm_medium=high-resolution-closed-loop-dispensing&utm_content=plan">Plan</a>, also enhances the user experience and control over output, allowing for multi-material printing of up to four stack-up layers, as well as making it possible to visualize and edit print jobs in a single workflow. Moreover, Plan offers an upgraded user experience in terms of minimizing print setup times and reducing the risk of failed prints by identifying possible errors in the planning stage.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1741080015164-Multilayer+printing+using+NOVA%E2%80%99s+Plan+feature.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Multilayer printing using NOVA's Plan feature.</span></span></span></p><h2 dir="ltr" id="isPasted">Researchers leverage NOVA for GI-monitoring device</h2><p dir="ltr">Voltera’s NOVA has been eagerly adopted by a number of research labs for a range of applications, including the development of <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">bioelectronics</a>, flexible <a href="https://multiplexed.mit.edu/wp-content/uploads/2023/06/transducers-2023-kachkine.pdf" data-lf-fd-inspected-kn9eq4roawkarlvp="true">displays and PCBs</a>, <a href="https://advanced.onlinelibrary.wiley.com/doi/full/10.1002/adem.202401302">materials research</a> and more. The platform’s ease of use and material versatility have also enabled researchers to explore the development of new and innovative materials for printed electronics, while advanced functions like the Smart Dispenser’s closed-loop pressure feedback and Plan software have given users access to professional, highly consistent results even at the prototyping stage. &nbsp;</p><p dir="ltr">NOVA was recently used by a research team out of the University of Southern California who were developing an ingestible electronic device to better monitor gas in the gastrointestinal (GI) tract for the diagnosis and monitoring of IBS, inflammatory bowel disease and other GI issues. NOVA was used to create wearable bend sensors to help locate the electronic pill inside the body (the pill itself is made from a PCB encapsulated in a 3D printed shell made from a biocompatible medical-grade resin). The bend sensors were made using stretchable carbon and silver inks on a PET substrate. According to the team’s research paper, published in&nbsp;Cell Reports Physical Science, NOVA offered them “high precision, reproducibility, and on-the-fly design modification capability”, all important factors when developing the non-invasive biomedical device.[3]</p><h2 dir="ltr">Transform your electronics prototyping</h2><p dir="ltr">Overall, Voltera’s NOVA platform and Smart Dispenser module give researchers and electronic product developers the means to rapidly and cost-efficiently test materials and create circuits and electronic devices with a high level of quality and consistency. This unprecedented capability opens the doors to the development of new and potentially game-changing devices, such as ingestible biosensors for health monitoring.&nbsp;</p><h3 dir="ltr">References</h3><p dir="ltr">[1] Why do we heat the Smart Dispenser? [Internet]. Voltera, 2024. <a href="https://docs.voltera.io/nova/learn-more/why-do-we-heat-the-smart-dispenser">https://docs.voltera.io/nova/learn-more/why-do-we-heat-the-smart-dispenser</a>&nbsp;</p><p dir="ltr">[2] Voltera. Voltera NOVA: Unboxing and First Time Setup [Internet]. Youtube, August 17, 2023. <a href="https://www.youtube.com/watch?v=dcAq5-zZj_Y">https://www.youtube.com/watch?v=dcAq5-zZj_Y</a>&nbsp;</p><p dir="ltr">[3] Abdigazy A, Arfan M, Shao J, Islam MS, Hassan MF, Khan Y. 3D gas mapping in the gut with AI-enabled ingestible and wearable electronics. Cell Reports Physical Science. 2024 Jul 17;5(7).</p>

Precision nozzle on NOVA’s Smart Dispenser

Discover how NOVA’s Smart Dispenser module unlocks consistent and high-precision trace printing for a range of ink viscosities.

High-Resolution Electronics Prototyping: Pushing the Limits with Closed-Loop Dispensing Systems

Power Management ICs are the silent architects of energy efficiency. Discover how these specialized integrated circuits optimize power delivery in everything from smartphones to electric vehicles!

PMIC Meaning: Understanding Power Management Integrated Circuits in Modern Electronics

<div data-message-author-role="assistant" data-message-id="fe87bb4d-a0d3-47fc-a297-e6810683272c" dir="auto" data-message-model-slug="gpt-4o" id="isPasted"><p data-start="0" data-end="550" data-is-last-node="">As demand for thinner, more adaptable electronics grows, advanced manufacturing techniques like printed electronics are enabling new possibilities. Flexible membrane keyboards are essential in industries ranging from consumer electronics to aerospace, offering a lightweight and durable alternative to traditional input devices. This article explores how Voltera’s NOVA materials dispensing system can be used to print a fully functional multilayer flexible membrane keyboard, leveraging conductive and dielectric inks for high-performance circuitry.</p><table style="width: 100%;"><tbody><tr><td style="width: 100%;"><h2 id="isPasted">Project overview</h2><p>The purpose of this project is to demonstrate how NOVA prints multilayer electrical circuits on a highly flexible substrate (PET), and dispenses ink with high precision on sections that are as small as 250 µm W × 40 µm H.</p></td></tr></tbody></table></div><h3 id="isPasted">Design layout</h3><h3><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/n3ZVfqWDtJU?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 450px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span>We divided the layout into three layers:</h3><ol><li>Base conductive layer (ACI SS1109 Stretchable Silver Ink)</li><li>Dielectric layer (ACI SI3104 Stretchable Printed Insulator)</li><li>Top conductive layer (ACI SS1109 Stretchable Silver Ink)</li></ol><h3>Desired outcome</h3><p>Based on a matrix style keyboard design, we limited the number of pins used to only seven on the controller (Arduino Micro, A000053). Once connected to a power source, pressing any key on the keyboard will trigger the controller to register the key.&nbsp;</p><h3>Functionality</h3><p>We determined a 10-numbered keypad design would be suitable for this project. However, other flexible membrane keyboard designs have the potential for further customization, such as specific graphics, colors, or lighting, which could be beneficial for specialized equipment, including customized control panels, wearable devices, and foldable electronics.</p><h2>Printing and curing the flexible substrate</h2><h3>Base conductive layer</h3><p>This layer consists of a 4’’ × 3’’ matrix grid for 10 numbered keys, excluding the 10 dielectric pads (see dielectric layer).</p><div data-message-author-role="assistant" data-message-id="fe87bb4d-a0d3-47fc-a297-e6810683272c" dir="auto" data-message-model-slug="gpt-4o" id="isPasted"><h2 id="isPasted"><br></h2></div><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739444252511-6709244d9b0c2b80f33a3fb9_670923005ab20b4c6a573338_Printing-flexible-membrane-keyboard-base-conductive-layer-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"></span></span></span></p><figure id="isPasted"><figcaption>Figure 2: Base conductive layer schematic</figcaption></figure><p></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443345372-6709244e9b0c2b80f33a4047_6709231c5bb93f90a2cdcfcf_Printing-flexible-membrane-keyboard-base-conductive-layer-printing.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 3: Base conductive layer being printed with NOVA<br></span></span></span></p><table id="isPasted" style="margin-right: calc(6%); width: 94%;"><tbody><tr><td>Ink</td><td>ACI SS1109 stretchable silver ink</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018333 dispensing tip, 0.25 mm inner diameter</td></tr><tr><td>Probe pitch</td><td>5 mm</td></tr><tr><td>Cure time and temperature</td><td>5 minutes at 135°C<br><br></td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443483052-6709244c9b0c2b80f33a3fac_67092339362ae204a8569f3b_Printing-flexible-membrane-keyboard-base-conductive-layer-print-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 4: NOVA print settings, base conductive layer</span></span></span></p><h3 id="isPasted">Dielectric layer&nbsp;</h3><p>This layer consists of 10 dielectric pads. To ensure full coverage of the dielectric ink, we did two passes for this layer, each cured after dispensing.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443515721-6709244c9b0c2b80f33a3fa9_67092356708e26b2cc8d222e_Printing-flexible-membrane-keyboard-dielectric-layer-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 5: Dielectric layer schematic</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443545964-6709244e9b0c2b80f33a3ffd_6709236e994543d8a36f6105_Printing-flexible-membrane-keyboard-dielectric-layer-print-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 6: Dielectric layer print result</span></span></span></p><table id="isPasted" style="margin-right: calc(2%); width: 98%;"><tbody><tr><td>Ink</td><td>ACI SI3104 stretchable printed insulator</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018424 dispensing tip, 0.15 mm inner diameter</td></tr><tr><td>Probe pitch</td><td>2 mm</td></tr><tr><td>Cure time and temperature</td><td>5 minutes at 135°C</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443594904-6709244d9b0c2b80f33a3fbe_67092388bd5f734676f835a5_Printing-flexible-membrane-keyboard-dielectric-layer-print-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 7: NOVA print settings, dielectric layer</span></span></span></p><h3 id="isPasted">Top conductive layer</h3><p>This layer consists of 10 fine crossover lines that connect the red signal paths and complete the circuitry.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443634342-6709244d9b0c2b80f33a3fb6_670923ababdea1f85b1530df_Printing-flexible-membrane-keyboard-top-conductive-layer-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 8: Top conductive layer schematic<br></span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443706201-6709244e9b0c2b80f33a3fd8_670923cfabdea1f85b154f1d_Printing-flexible-membrane-keyboard-top-conductive-layer-print-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 9: Top conductive layer print result with crossovers</span></span></span></p><table id="isPasted"><tbody><tr><td>Ink</td><td>ACI SS1109 stretchable silver ink</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018333 dispensing tip, 0.25 mm inner diameter</td></tr><tr><td>Probe pitch</td><td>2 mm</td></tr><tr><td>Cure time and temperature</td><td>5 minutes at 135°C</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739443957434-6709244e9b0c2b80f33a3fe4_670923ef79f68cb3137c9c83_Printing-flexible-membrane-keyboard-top-conductive-layer-print-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 10: NOVA print settings, top conductive layer</span></span></span></p><h2 id="isPasted">Challenges and advice for printing multilayer</h2><h3>Broken layers</h3><p>Because inks from different manufacturers have different properties – they may contain solvents that dissolve existing traces for example – printing and curing each new layer risks breaking the layer previously completed. It is, therefore, crucial that you choose compatible materials based on the degree of flexibility required.</p><p>For this project, we selected compatible inks from ACI Materials, but for projects that involve using multiple inks from different manufacturers, it is recommended that you <strong>check the materials’ technical data sheets</strong>.</p><h3>Electrical shorts</h3><p>Due to the matrix design of the keyboard, the signal lines have a number of crossovers, which could cause electrical shorts if not insulated properly.</p><p>Printing a second pass of the dielectric layer achieves an appropriately thick insulating layer and supports further printing on top.&nbsp;</p><h3>Connection issues</h3><p>Because the crossover sections are intricate (250 µm W × 40 µm H), if the nozzle scratches the ink while printing, the electrical paths may not function as planned.</p><p>Separating the crossover sections into their own layer (the top conductive layer) allows each crossover pad to be probed accurately and have specialized settings, yielding a higher success rate.</p><p>In addition, because changes in height can happen drastically when printing over existing traces, setting a low probe pitch will make the height map more accurate. An accurate height map means the height transition at the edges of features is accurate and the risk of traces being printed off-course is low.</p><h2>Post-printing: A fully flexible electronic device</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739444024604-6709244e9b0c2b80f33a400f_6709241ab070d58e6f035de8_Printing-flexible-membrane-keyboard-post-printing-fully-flexible-electronic-device.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 11: Flexible keyboard assembly</span></span></span></p><p id="isPasted">To ensure the Arduino Micro was securely in place, we used a FR1 board, cut it to 30 mm × 60 mm, and placed it beneath the flexible substrate (PET sheet). Next we drilled through holes on the board and the flexible substrate with the <a href="https://www.voltera.io/v-one">Voltera V-One PCB printer</a>.</p><p>We then dispensed solder paste, placed the diodes on the flexible substrate, and riveted it together with the FR1 board, before placing the metal switches on the rectangle-shaped contacts. To secure the metal switches, we covered them with Kapton tape.</p><p>Next, we secured the controller to the flexible substrate and connected it to a power source. We also gave the keyboard a finishing touch by placing it inside a 3D-printed enclosure with graphical silicone keys.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1739444076871-6709244d9b0c2b80f33a3fd3_67092437df6f44a8a78c9bfb_Printing-flexible-membrane-keyboard-post-printing-final-hard-case.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 12: Final assembly in 3D-printed case</span></span></span></p><h2 id="isPasted">Conclusion&nbsp;</h2><p>This project highlights the innovative potential of printing on flexible substrates. It also points to the critical role of fine-tuning print settings to achieve success in multilayer projects.&nbsp;</p><p>As achieved by this project, using compatible materials helps ensure optimal performance, and is key to unlocking the full potential of flexible electronics. As we continue to explore the boundaries of what’s possible with flexible substrates, we invite you to view the <a href="https://www.voltera.io/applications">other projects</a> we’ve completed.</p>

Figure 1: Three layered print with crossovers

Flexible membrane keyboards are used in a variety of electronics, medical devices, automotive, and more due to their thin, lightweight design. This project demonstrates printing one using Voltera’s NOVA system.

Advancing Flexible Electronics: Printing Multilayer Membrane Keyboards with Conductive Inks

<p dir="ltr" id="isPasted">In the world of electronic manufacturing, printed circuit boards (PCBs) still reign. However, their applications have remained limited due to their rigid nature. <a href="https://www.wevolver.com/article/beyond-rigidity-the-rise-of-flexible-electronics">Flexible electronics</a> have therefore been on the rise as an alternative to PCBs, offering electronic circuits that can bend, stretch, and even wrap around other objects. This adaptability enables them to be integrated into a wider variety of surfaces and products. However, single layer flexible electronics lack the advanced performance capabilities of rigid PCBs, which also creates limitations in terms of their use. That’s where Flexible Multilayer Electronics come in. This emerging type of circuitry, made possible through technologies like <a href="https://www.voltera.io/nova?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=voltera-nova-materials-dispensing-system">Voltera’s NOVA platform</a>, delivers the benefits of flexible electronics while enabling more complex functions.</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/tG3YzCNbIs0?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h1 dir="ltr" id="isPasted">What Are Flexible Multilayer Electronics?</h1><p dir="ltr">Flexible Multilayer Electronics bear some similarities to Flexible Hybrid Electronics (FHE), which bridge the divide between PCBs (powerful but rigid) and <a href="https://www.wevolver.com/article/unfolding-the-future-the-evolution-and-impact-of-printed-electronics">flexible printed electronics</a> (bendable but largely limited to simple applications like sensors and displays).[1] &nbsp;However, unlike FHEs, Flexible Multilayer Electronics do not include rigid PCBs or integrated circuits (ICs). Instead, they build on functionality by layering circuitry printed onto flexible substrates. The result is electronics that are more complex in their functionality and highly conformable.</p><p dir="ltr">One of the defining characteristics of flexible electronics is the use of flexible substrates, such as PET or TPU. Stretchable conductive inks, such as <a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml?srsltid=AfmBOoo-2VuBmvxICSPKhwel9it5mZb6gX_XPbTXW78qxv56d85MN8Q2">Stretchable Silver Ink</a> are then applied to the substrate using a precision printing process, such as <a href="https://www.voltera.io/blog/introduction-inkjet-technology?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=inkjet-printing">inkjet printing</a> or <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=direct-ink-writing">direct ink writing</a>. With Flexible Multilayer Electronics, this initial base layer is followed by the application of a dielectric layer, where an insulating ink is selectively printed onto the base layer. From there, the third layer, or crossover layer, can be applied, which adds further conductive properties to the circuit.&nbsp;</p><p dir="ltr">The functionality of Flexible Multilayer Electronics has obvious benefits, such as being able to create stretchable, lightweight, and compact electronics that can conform to a wide variety of surfaces, like textiles, IoT devices, and even skin.&nbsp;</p><h1 dir="ltr">The Technology Enabling Flexible Multilayer Electronics Development</h1><p dir="ltr">The ability to manufacture Flexible Multilayer Electronics has recently been unlocked on <a href="https://www.voltera.io/nova?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=voltera-nova-materials-dispensing-system">Voltera’s NOVA materials dispensing system</a> thanks to a recent Plan software upgrade. NOVA, a printing platform for flexible hybrid electronics R&amp;D and novel materials research, enables the printing of viscous materials onto various substrates. This includes flexible PET, stretchable TPU, conformable paper, and biocompatible polyimide, as well as rigid substrates like FR1, FR4, silicon wafers, and more. &nbsp;NOVA is particularly notable for its ability to print a wide range of materials with viscosities ranging from 1,000 to 1,000,000 cps. In practice, this means NOVA can process a variety of conductive, dielectric, or functional inks, as well as gels and pastes.[2]&nbsp;</p><p>NOVA is a useful tool for prototyping flexible multilayer electronics as well as making custom electronics, materials testing, and manufacturing low-volume batches. These capabilities are further enhanced thanks to the company’s latest software feature, Plan. This software upgrade is integral to the production of Flexible Multilayer Circuits as it enables users to print up to four stackup layers for enhanced functionality and gives users greater control over the sequence of trace printing.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM4NjczNDk4ODU0LWZsZXhpYmxlLW11bHRpbGF5ZXItZGVzaWducy1ub3ZhLXByaW50aW5nLW11bHRpbGF5ZXIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">NOVA dispensing ink for a multilayer sensor.</span></span></span></p><p dir="ltr" id="isPasted">More specifically, Plan allows users to visualize and edit the print sequence of multilayer electronic designs, while identifying potential errors before the printing begins. The tool also automatically generates smart probe points, which results in more accurate heightmaps based on the layer stackup. These features ultimately unlock the creation of repeatable, consistent multilayer prints and facilitate the production of multi-signal paths, complex sensor networks, and more complex routing in flexible electronics.</p><p dir="ltr">Voltera developed NOVA with the aim of transforming how printed electronics—in particular, flexible electronics—are developed and manufactured. The modular printing platform empowers users to develop, iterate and test flexible electronics, as well as custom materials, in a time- and cost-efficient manner. For example, users can iterate their flexible electronic designs in-house within just a day, rather than having to wait days or weeks through a vendor. For multilayer designs, being able to iterate in-house and identify errors before printing is notably beneficial, since more traditional production methods for multilayer electronics, like screenprinting, which typically necessitate working with external vendors, can be incredibly time consuming and require significant back and forth before a correct screen design is reached.</p><p dir="ltr">On top of that, NOVA allows for more economical material use, since the conductive and dielectric inks are applied selectively and with precision, unlike screen printing methods that consume more material, requiring a screen for every layer. These material and cost advantages are especially notable in multilayer prints, where screenprinting additional layers can drive up costs significantly. By contrast, with NOVA, the only added costs are for the ink used in the extra layers.&nbsp;</p><h1 dir="ltr">Applications of Flexible Multilayer Electronics</h1><p dir="ltr">Understandably, the ability to rapidly iterate and make Flexible Multilayer Electronics will have big impacts in industries like healthcare, defense, and consumer electronics, all of which can benefit from lightweight, conformable, and highly functional electronics. Below are just a few examples of how end users are exploring the use of flexible electronics and how multilayer printing could transform these applications.</p><h3 dir="ltr">Biosensing</h3><p>In the healthcare sector, flexible multilayer electronics are opening up unprecedented opportunities when it comes to health monitoring and biosensing. More specifically, integrated circuitry and sensors on flexible and biocompatible substrates can be used for a range of medical uses, including diagnostics, drug delivery, and general wellness tracking. Flexible multilayer electronics can be placed directly on the body or integrated into a wearable device to gather valuable data on things like glucose levels, intracranial pressure, wound monitoring, and more.[3] For example, Voltera recently demonstrated the ability to print <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=ecg-electrodes">multi-material ECG sensors</a> using biocompatible gold and stretchable silver ink—a function facilitated by Plan software.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM4NjczNTUxODU1LWZsZXhpYmxlLW11bHRpbGF5ZXItZGVzaWducy1lY2ctZWxlY3Ryb2Rlcy1nb2xkLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">NOVA dispensing ink for ECG electrodes</span></span></span></p><h3 dir="ltr" id="isPasted">Field Operations</h3><p dir="ltr">Flexible multilayer electronics can also be game-changing for field operations in the automotive and defense sectors. There are many possible uses for flexible multilayer electronics: for example, they can be used in harsh environments, offering ruggedized, conformable electronics that can be mounted on vehicles, drones, soldiers, and robots. The U.S. Department of Defense, for instance, has invested in flexible electronics with the aim of advancing applications like soldier network authentication, infrastructure monitoring [4], communications systems, and even drone operations.[5] In this vertical, multilayer printing capabilities could enable greater functionality for conformable sensors and faster development times for new devices.&nbsp;</p><h3 dir="ltr">Consumer Electronics</h3><p>With the growing demand for miniaturization in the consumer electronics industry, flexible multilayer electronic technology is playing an increasingly important role. With the ability to integrate more complex circuitry and multiple materials on flexible, stretchable substrates, consumer electronics companies are ushering in new and innovative products like smartphones with foldable screens, electronic textiles, and compact, flexible batteries. For example, Huawei released a smartphone with a screen that folds three ways, which when unfolded is the slimmest phone ever.[6] Additionally, Voltera recently designed a <a href="https://www.voltera.io/use-cases/white-papers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=multilayer-flexible-membrane-keyboard">multilayer flexible membrane keyboard</a>. This design, which integrated three layers, resulted in a thin, lightweight keyboard that could have applications in portable electronics, toys, home appliances, and more.</p><h1 dir="ltr" id="isPasted">The Future of Flexible Multilayer Electronics</h1><p dir="ltr">The field of Flexible Multilayer Electronics is a burgeoning one and its potential only continues to grow as applications evolve and production platforms like Voltera’s NOVA make flexible electronics development more accessible to researchers and product developers through its short turnaround times and versatile material choice. Interestingly, the ongoing growth and advancement of flexible electronics is very much the result of multi-disciplinary collaboration. Engineers, researchers, and electronics companies and manufacturers are coming together to develop new solutions and usher in a new era for wearable devices and conformable electronics.&nbsp;</p><p dir="ltr">For example, researchers based out of Polytechnique Montreal are leveraging Voltera’s NOVA to develop bioelectronics that use self-healing materials as a substrate. Among the projects being pursued are flexible sensors that can be mounted on violin bows to improve performance and tennis rackets that help minimize the risk of injury.[7]</p><p>Voltera also demonstrated NOVA’s ability to produce Flexible Multilayer Electronics by printing an electroluminescent, <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=blue-light-emitting-pattern">blue-light-emitting pattern onto both a paper and PET substrate</a>. This project, which leveraged electroluminescent ink, consisted of printing four layers: a base conductive layer, a dielectric layer, a phosphor layer (necessary for the electroluminescent effect), and a top conductive layer. The result was a glowing circuit in the pattern of Voltera’s logo—a capability that the company says could be extended to applications like billboards, control panels, and branded merchandise.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM4NjczNTg4NjM3LWZsZXhpYmxlLW11bHRpbGF5ZXItZGVzaWducy1lbGVjdHJvbHVtaW5lc2NlbnQtY2lyY3VpdC1wYXBlci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Electroluminescent circuit printed by NOVA</span></span></span></p><p dir="ltr" id="isPasted">This is truly just the tip of the iceberg when it comes to the future of Flexible Multilayer Electronics. The emerging field is developing quickly and is ripe for innovation. Whether you’re looking to develop flexible multilayer circuits in-house, printing novel electronics, or testing materials for your research, contact <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=book-a-meeting">Voltera to learn more</a>.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Franz, Jillian.<a href="https://www.voltera.io/blog/flexible-hybrid-electronics?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=what-are-fhe">&nbsp;What are Flexible Hybrid Electronics?</a> [Internet]. Voltera, December 8, 2024.&nbsp;</p><p dir="ltr">[2] <a href="https://www.voltera.io/nova?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=voltera-nova-materials-dispensing-system">NOVA materials dispensing system</a> [Internet]. Voltera, 2024.&nbsp;</p><p dir="ltr">[3] Next-generation health monitoring requires the integration of flexible hybrid electronics (FHE) [Internet]. Medical Design &amp; Outsourcing, November 6, 2023. <a href="https://www.medicaldesignandoutsourcing.com/flexible-hybrid-electronics-fhe-next-generation-health-monitoring/">https://www.medicaldesignandoutsourcing.com/flexible-hybrid-electronics-fhe-next-generation-health-monitoring/</a>&nbsp;</p><p dir="ltr">[4] DOD awards $154 million to Army-led flexible electronics project [Internet]. U.S. Army, July 15, 2020. <a href="https://www.army.mil/article/237275/dod_awards_154_million_to_army_led_flexible_electronics_project">https://www.army.mil/article/237275/dod_awards_154_million_to_army_led_flexible_electronics_project</a>&nbsp;</p><p dir="ltr">[5] Flexible Hybrid Electronics Demonstrator for UAV Applications. Department of Defense Manufacturing Innovation Institutes. <a href="https://www.dodmantech.mil/Portals/107/Flexible%20Hybrid%20Electronics%20Demonstrator%20for%20UAV%20Applications%20%20NextFlex.pdf" data-lf-fd-inspected-kn9eq4roawkarlvp="true">https://www.dodmantech.mil/Portals/107/Flexible%20Hybrid%20Electronics%20Demonstrator%20for%20UAV%20Applications%20%20NextFlex.pdf</a>&nbsp;</p><p dir="ltr">[6] Dayaram, Sareena. Mate XT Ultimate Design: What It Was Like Using Huawei's Sexy Triple-Screen Phone [Internet]. CNET, Oct. 2, 2024. <a href="https://www.cnet.com/tech/mobile/what-it-was-like-using-mate-xt-ultimate-design-huaweis-tri-folding-phone/">https://www.cnet.com/tech/mobile/what-it-was-like-using-mate-xt-ultimate-design-huaweis-tri-folding-phone/</a>&nbsp;</p><p dir="ltr">[7] <a href="https://www.voltera.io/use-cases/customer-stories/polytechnique-montreal?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=wevolver&utm_medium=article&utm_term=flexible-multilayer-electronics&utm_content=polytechnique-montreal">Polytechnique Montréal: Researching Printed Stretchable Bioelectronics with Voltera NOVA and V-One</a> [Internet]. Voltera, 2024.&nbsp;</p>

NOVA dispensing ink for a flexible membrane keyboard

Flexible Multilayer Electronics combine flexibility with advanced functionality, enabling applications in wearables, biosensors, defense, and consumer electronics. This article explores how technologies like Voltera’s NOVA platform are making their development more accessible.

Electronics That Bend the Rules: The Benefit of Flexible Multilayer Designs

Surface Mount Technology (SMT) revolutionized electronics manufacturing by enabling smaller, faster, and more efficient circuit designs. This guide delves into the core principles of SMT, explores its cutting-edge advancements, and addresses the challenges in implementing this technology.


What is SMT: A Comprehensive Guide to Surface Mount Technology

Microprocessor vs Integrated Circuit (IC)

This article explains, how is a microprocessor different from an integrated circuit, exploring their key differences, architectures, technological advancements, and potential applications.

How is a Microprocessor Different from an Integrated Circuit?

IPC Class System - Development and Design of Electronic Devices

This technical guide explores the framework of IPC classes, their hierarchical structure, modern implementation methodologies, and the significant role they play in the global intellectual property landscape.

IPC Class System: A Technical Deep Dive into Patent Classification Architecture

Single Sided PCB with Solder Mask and Surface Mount Components

In this comprehensive guide, we will explore the design, manufacturing process, advantages, and limitations of single sided PCBs, helping you understand their critical role in modern electronics.

Single Sided PCB: A Comprehensive Guide

Explore how PCB drilling forms the backbone of modern electronics by enabling seamless circuit connectivity and ensuring robust device performance. Learn practical insights and expert tips to optimize your manufacturing process.

PCB Drilling: Precision Techniques for Modern Electronics

<p id="isPasted">Voltera's recent project showcases the successful prototyping of a flexible, multilayer LED roulette circuit using silver ink on a polyethylene terephthalate (PET) substrate. Traditionally fabricated on rigid materials like FR4, this innovative approach demonstrates the potential of flexible electronics in educational settings and beyond.</p><p>The redesigned circuit comprises three layers: a base conductive layer, a dielectric layer, and a top conductive layer. Each layer maintains flexibility after curing, ensuring the circuit's integrity even after encapsulation and repeated bending. When powered, the circuit emulates a roulette wheel, with LEDs lighting up in a rapid circular sequence before slowing down and stopping on a single LED.</p><p>This project underscores the educational value of converting rigid circuit designs into flexible ones, allowing students to explore diverse materials and optimize print settings through experimentation. It also demonstrates the potential of prototyping flexible PCBs to replace electronics that were considered rigid, achieving lightweight, compact, and resilient designs.</p><h2 id="isPasted">Project Overview</h2><h3>Purpose</h3><p>The goal of this project was to prototype a flexible multilayer LED wheel roulette circuit that was traditionally considered rigid and validate the redesign of the circuit.&nbsp;</p><h3>Design&nbsp;</h3><p>This project involves a multilayer <a href="https://www.voltera.io/blog/flexible-hybrid-electronics">flexible PCB</a> for the LED roulette circuit and a traditional control board that powers it. We adapted the design of an LED roulette circuit, originally developed for a 3” × 4” FR4 board by <a href="http://itiz.co.kr/">ITIZ</a>, Voltera’s authorized reseller in Korea. This new version is printed on a coated biaxially oriented PET substrate, allowing the circuit to remain flexible — even when populated with components.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/FCSASyN0K3I?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><p id="isPasted">We divided the LED roulette circuit design into three layers:</p><ul><li>Base conductive layer</li><li>Dielectric layer</li><li>Top conductive layer</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736264031443-673b86072c4ed105d1f99a64_673b81e19467b3fc401543a5_flexible-pcb-itiz-led-roulette-circuit.webp" style="width: 100%px;" class="fr-fic fr-dib" alt="Figure 1: Original LED roulette circuit design by ITIZ"><span class="fr-inner">Figure 1: Original LED roulette circuit design by ITIZ</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736264068537-673b86072c4ed105d1f99a58_673b820e2668f8a32be1be4c_flexible-pcb-led-roulette-circuit-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 2: Voltera modified design of the LED roulette circuit</span></span></span></p><h3 id="isPasted">Desired outcome</h3><p>We anticipated the circuit would function like a roulette wheel: each time the pulse generator is triggered, the LEDs on the flexible PCB light up in a rapid circular sequence before slowing down and stopping on a single LED.</p><h3>Functionality</h3><p>By printing a dielectric and crossover layer on top of the base conductive layer, we created a compact and lightweight LED roulette circuit without using jumpers. Each layer remained flexible after curing, and the circuit maintained its integrity even after encapsulation and repeated flexing.&nbsp;</p><p>When connected to power, pressing the switch on the control board caused the LEDs on the flexible PCB to light up, replicating the behavior of a roulette wheel as intended.</p><h2>Printing the control board</h2><p>This board controls the pulse signals and powers the LED roulette wheel circuit. We used V-One to print the circuit and reflow the components, which included:</p><ul><li>NE555DR timer</li><li>LED</li><li>Switch</li><li>47 µF capacitor</li><li>0.1 µF capacitor</li><li>10 nF capacitor</li><li>100 kΩ resistor</li><li>330 Ω resistor</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265263814-673b86072c4ed105d1f99a5b_673b825108fc1d87420a0c06_flexible-pcb-led-control-board-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 3: Schematic for the control board</span></span></span></p><table id="isPasted" style="margin-right: calc(2%); width: 98%;"><tbody><tr><td>Ink</td><td>Voltera Conductor 3 silver ink</td></tr><tr><td>Substrate</td><td>2" x 3" FR1 board</td></tr><tr><td>Nozzle type</td><td>Voltera disposable nozzle</td></tr><tr><td>Probe pitch</td><td>5 mm</td></tr><tr><td>Probe time</td><td>4 minutes 38 seconds</td></tr><tr><td>Print time</td><td>4 minutes 51 seconds</td></tr><tr><td>Reflow time and temperature</td><td>140°C for 2 minutes, and then 190°C for 30 seconds</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265304401-673cbad5909c9ae473ff0408_673cba9cd0a8c205bdb84721_flexible-pcb-led-circuit-control-board.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 4: The control board</span></span></span></p><h2 id="isPasted">Printing the flexible PCB</h2><p>This flexible PCB receives signals from the control board and lights up the LEDs as directed.&nbsp;</p><h3>Base conductive layer</h3><p>This layer consists of a roulette-shaped circuit (90 mm L × 70 mm W) that connects to the control board, as well as power and ground terminals, with designated gaps for dielectric pads.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265338873-673b86072c4ed105d1f99a6a_673b83d197286b4449739ba7_flexible-pcb-base-conductive-layer-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 5: Schematic for the base conductive layer</span></span></span></p><table id="isPasted" style="margin-right: calc(2%); width: 98%;"><tbody><tr><td>Ink</td><td>ACI Materials FS0142 Semi-Sintering Conductive Ink</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018395 dispensing tip, 200 µm inner diameter</td></tr><tr><td>Probe pitch</td><td>5 mm</td></tr><tr><td>Probe time</td><td>3 minutes 4 seconds</td></tr><tr><td>Print time</td><td>14 minutes 42 seconds</td></tr><tr><td>Cure time and temperature</td><td>150°C for 15 minutes</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265373191-673b86072c4ed105d1f99a5e_673b840520cda3b3ae547ba5_flexible-pcb-nova-settings-base-layer.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 6: NOVA print settings, base conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265456158-673b86092c4ed105d1f99acb_673b84262760f4b16bd4c131_flexible-pcb-layer-one-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 7: Print result, base conductive layer</span></span></span></p><h3 id="isPasted">Dielectric layer</h3><p>This layer consists of 29 dielectric pads that provide insulation for the top conductive layer. For better coverage, we printed two passes of dielectric ink.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265494072-673b86072c4ed105d1f99a49_673b844b15838b3c71a77804_flexible-pcb-led-dielectric-layer-schematic.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 8: Schematic for the dielectric layer</span></span></span></p><table id="isPasted"><tbody><tr><td>Ink</td><td>ACI Materials SI3104 Stretchable Printed Insulator</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018424 dispensing tip, 150 µm inner diameter</td></tr><tr><td>Probe pitch</td><td>5 mm</td></tr><tr><td>Probe time</td><td>2 minutes 8 seconds</td></tr><tr><td>Print time</td><td>6 minutes 32 seconds</td></tr><tr><td>Cure time and temperature</td><td>135°C for 15 minutes</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265639299-673b86072c4ed105d1f99a67_673b84768e7d474c7d82fe5a_flexible-pcb-dielectric-layer-nova-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 9: NOVA print settings, dielectric layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265680668-673b86082c4ed105d1f99aa8_673b84969b09b4b9a3bb6490_Flexible-pcb-layer-two-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 10: Print result, dielectric layer</span></span></span></p><h3 id="isPasted">Top conductive layer</h3><p>This layer consists of 29 fine crossover traces that connect the paths to the power terminal and control board. To address potential gaps over height changes, we decreased the trace width to 100 mm to enhance trace continuity.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265759141-figure11.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 11: Schematic for the top conductive layer</span></span></span></p><table id="isPasted"><tbody><tr><td>Ink</td><td>ACI Materials FS0142 Semi-Sintering Conductive Ink</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson EFD 7018395 dispensing tip, 200 µm inner diameter</td></tr><tr><td>Probe pitch</td><td>1 mm</td></tr><tr><td>Probe time</td><td>2 minutes 46 seconds</td></tr><tr><td>Print time</td><td>2 minutes 26 seconds</td></tr><tr><td>Cure time and temperature</td><td>150°C for 15 minutes</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736265828830-673b86072c4ed105d1f99a5e_673b840520cda3b3ae547ba5_flexible-pcb-nova-settings-base-layer+%281%29.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 12: NOVA print settings, top conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736328961304-673b86082c4ed105d1f99aa2_673b8513e8c7693a1d09a24f_flexible-pcb-layer-three-crossovers.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 13: Print result, bottom conductive layer</span></span></span></p><h2 id="isPasted">Post-processing the flexible PCB</h2><h3>Dispensing solder paste and reflowing the components</h3><p>Once the circuit was cured, we dispensed solder paste using NOVA and populated the components before reflowing them in an oven.</p><table><tbody><tr><td>Ink</td><td>Voltera T4 solder paste</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson general purpose dispense tip, 410 µm inner diameter, blue</td></tr><tr><td>Probe time</td><td>2 minutes 6 seconds</td></tr><tr><td>Print time</td><td>4 minutes 39 seconds</td></tr><tr><td>Cure time and temperature</td><td>150°C for 2 minutes</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736329002882-673b86072c4ed105d1f99a4c_673b853808fc1d87420c376a_flexible-pcb-nova-settings-solder-paste.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 14: NOVA print settings, solder paste</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736329054751-673b86082c4ed105d1f99a86_673b855a8af066bbb936caec_flexible-pcb-solder-dispensing.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 15: NOVA dispensing solder paste</span></span></span></p><p id="isPasted">Because the wires are not heat-resistant, we manually soldered them onto both the companion board and the flexible roulette circuit.</p><h3>Encapsulating the components</h3><p>To reinforce their connection to the substrate, we dispensed encapsulation resin using a syringe onto the components and cured the resin in a UV light box.</p><table><tbody><tr><td>Ink</td><td>Siraya Tech Tenacious Flexible Resin</td></tr><tr><td>Substrate</td><td>PET</td></tr><tr><td>Nozzle type</td><td>Nordson general purpose dispense tip, 330 µm inner diameter, orange</td></tr><tr><td>Cure time and temperature</td><td>Room temperature for 2 minutes under UV light</td></tr></tbody></table><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736329090939-673b86082c4ed105d1f99aa5_673b857fcd2ccc2a63c43e16_flexible-pcb-uv-curing-resin.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 16: Encapsulated circuit being cured in a UV light box</span></span></span></p><p id="isPasted">Once cured, we manually soldered the wires of the control board and the wires of the flexible roulette circuit together.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736329135793-673b86072c4ed105d1f99a6e_673b85ac08fc1d87420c84c7_flexible-pcb-led-manual-solder-wire.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 17: Soldering the wires together</span></span></span></p><h2>Challenges and advice</h2><h3>Electrical shorts</h3><p>We encountered issues with shorts due to multiple crossover lines on the dielectric layer. To address this, we recommend printing a second pass of the dielectric layer to achieve a thicker insulating layer that better supports additional layers printed on top.</p><h3>Drastic height changes</h3><p>A second pass of the dielectric layer can result in significant height differences. To handle this, it is advisable to set a low probe pitch to ensure a more accurate height map and print a thicker crossover layer for improved contact on the top layer.</p><h3>Maintaining flexibility with components attached&nbsp;</h3><p>To ensure the circuit remained flexible after populating components, we opted for smaller, more flexible components. This, combined with the use of a flexible substrate, encapsulant, and inks, allowed the circuit to bend without damaging the connections.</p><h2>Conclusion</h2><p>This project highlights the educational value of converting rigid circuit designs into flexible ones, allowing students to explore diverse materials and optimize print settings through experimentation. It also demonstrates the potential of prototyping flexible PCBs to replace electronics that were considered rigid, achieving lightweight, compact, and resilient designs.</p><p>As flexible PCBs gain more popularity, hands-on experience with these technologies becomes essential for staying ahead in the rapidly evolving electronics industry. We invite you to explore our <a href="http://www.voltera.io/applications">other projects</a> as we continue to explore the possibilities of flexible PCBs and printed electronics.</p>

LED applications are a staple of engineering school projects, combining hands-on learning with creativity. Among these, the LED roulette is a favorite, offering both intellectual challenge and engaging interactivity. 

Illuminating Innovation: How to Print a Flexible PCB with Silver Ink on PET

<h2 id="isPasted">Project overview</h2><h3>Purpose</h3><p>The purpose of this project was to demonstrate the multilayer capability of <a href="https://www.voltera.io/nova">Voltera NOVA</a>. We printed a blue light-emitting pattern — the Voltera logo — on two substrates: paper and PET separately, using electroluminescent ink.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/Yc8nEoVnpDY?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 450px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h3 id="isPasted">Design layout</h3><p>Electroluminescence operates by exciting a phosphor material with an electric field. An inverter is needed to convert the direct current from the power source into alternating current.</p><p>Based on this mechanism, our design positions a phosphor layer between two conductive layers, incorporating a dielectric ink layer to insulate the phosphor. The printing sequence is as follows:</p><ul><li>Layer 1: Base conductive layer&nbsp;</li><li>Layer 2: Dielectric layer&nbsp;</li><li>Layer 3: Phosphor layer</li><li>Layer 4: Top conductive layer</li></ul><h3>Layer overview</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492862692-67091c8ba38b9d9305e349bd_67091ae09acab270adbdf20e_Printing-electroluminescent-ink-paper-pet-layer-overview.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Desired outcome</h3><p>Once connected to an alternating current (140 V, 1.862 kHz), the phosphor layer emits blue light, illuminating the Voltera logo with an even glow across both prints.</p><h3>Functionality</h3><p>We determined the Voltera logo would be suitable for this project. It is feasible to incorporate designs into larger electronic applications, including billboards, branded merchandise, and control panels.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492887115-67091c8ca38b9d9305e34a1b_67091b02bdc7f308274e583c_Printing-electroluminescent-ink-paper-pet-functionality.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Final print on paper<br></span></span></span></p><h2 id="isPasted">Printing the electroluminescent Voltera logo</h2><h3>Base conductive layer</h3><p>This layer consists of a Voltera logo pattern (55.5 mm L × 19.75 mm W) and positive and negative traces that connect to power and ground terminals.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492929241-67091c8ba38b9d9305e349c3_67091b1d9aa70f5ad577fd0b_Printing-electroluminescent-ink-base-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, base conductive layer<br></span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492948899-67091c8ba38b9d9305e349d2_67091b3ba4c7564aec9fc4c0_Printing-electroluminescent-ink-base-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, base conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492971049-67091c8ca38b9d9305e34a00_67091b566f34a25480b46ae4_Printing-electroluminescent-ink-base-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, base conductive layer</span></span></span></p><h3 id="isPasted">Dielectric layer</h3><p>This layer features a dielectric Voltera logo pattern which measures 23 mm L × 15 mm W and two dielectric pads. These extra pads help ensure the top conductive layer is appropriately insulated.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493165129-67091c8ba38b9d9305e349c0_67091b7716905ac65aa4e290_Printing-electroluminescent-ink-dielectric-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, dielectric layer</span></span></span></p><h3><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493233623-67091c8ba38b9d9305e349cf_67091b9107b512cf5a4ae562_Printing-electroluminescent-ink-dielectric-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, dielectric layer<br></span></span></span></h3><h3><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493246956-67091c8ca38b9d9305e34a15_67091bafbdc7f308274eea1a_Printing-electroluminescent-ink-dielectric-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, dielectric layer</span></span></span></h3><h3 id="isPasted">Phosphor layer</h3><p>This layer contains a Voltera logo pattern, slightly smaller than the dielectric layer (by 0.5 mm each way), printed with blue light-emitting ink.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493315418-67091c8ba38b9d9305e349c9_67091bcf07c69e92aba81f70_Printing-electroluminescent-ink-phosphor-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, phosphor layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493337007-67091c8ba38b9d9305e349d5_67091be50886a22f6b31099d_Printing-electroluminescent-ink-phosphor-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, phosphor layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493358134-67091c8ca38b9d9305e34a1e_67091c028b83f4ea5977853c_Printing-electroluminescent-ink-phosphor-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, phosphor layer</span></span></span></p><h3 id="isPasted">Top conductive layer</h3><p>Lastly, this layer includes a conductive overlay with an opening at the bottom left to prevent short circuiting. It measures 29.5 mm L × 21.5 mm W and connects to the ground terminal.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493385109-67091c8ba38b9d9305e349db_67091c23c63ef691b7477c26_Printing-electroluminescent-ink-top-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, top conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493412343-67091c8ca38b9d9305e34a12_67091c394819899b375fb8eb_Printing-electroluminescent-ink-top-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, top conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493430542-67091c8ca38b9d9305e34a18_67091c534ec56a943f81fc4f_Printing-electroluminescent-ink-top-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, top conductive layer</span></span></span></p><h2 id="isPasted">Challenges and advice for printing multilayer electroluminescent displays</h2><h3>Trapped air</h3><p>Air bubbles can form in inks that have been left unused for an extended period. These bubbles caused the dielectric layer to break when we cured it in the oven.&nbsp;</p><p>Mixing the ink with a dual asymmetric centrifugal mixer before printing will eliminate air bubbles. Additionally, it is recommended to allow the dielectric layer to dry naturally at room temperature instead of curing it in an oven.&nbsp;</p><h3>Uneven glow&nbsp;</h3><p>During our experiments, some prints exhibited dark areas, leading to an uneven glow. This issue can arise from several factors:&nbsp;</p><ul><li>The top conductive layer being too thick</li><li>The phosphor layer being too thin or getting scratched off during dispensing of the ink for the top conductive layer</li><li>Irregularities in print height</li></ul><p>Adding fiducials to each layer helps improve alignment and print quality. In terms of print settings, if the layer is too thick, increasing the print speed, reducing the height (we reduced it to approximately 40 µm), and using a smaller nozzle can be helpful. If the layer is too thin, try to reduce the print speed.&nbsp;</p><p>Furthermore, in multilayer projects, changes in height can happen drastically when printing over existing traces. Setting a low probe pitch will make the height map more accurate, ensuring the height transition at the edges of features is accurate and reducing the risk of traces being printed off-course.</p><h2>Conclusion</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493470103-67091c8ca38b9d9305e34a03_67091c71bdc7f308274f8ff7_Printing-electroluminescent-ink-paper-pet-conclusion.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Electroluminescent logo final print</span></span></span></p><p id="isPasted">The paper substrate provided consistent results throughout our experimentation, due to its absorbent nature. Each layer was smoother on paper than on PET, highlighting the potential of using paper as a substrate in EL display applications. &nbsp;</p><p>On the other hand, PET, being flexible and chemically resistant, offers the advantage of suitability for more demanding use cases. As demonstrated by this project, with careful attention and fine-tuning of the print settings, the results of EL display on PET are equally impressive.</p><p>EL displays are also intriguing when printed on glass and other non-conductive substrates. As we continue to explore the possibilities of electroluminescent inks, we invite you to view the&nbsp;<a href="https://www.voltera.io/applications">other projects</a> we’ve completed.</p>

Due to their consistent brightness, low cost and high energy efficiency, electroluminescent inks are used in a wide range of electroluminescent display applications. This project is an example of printing an electroluminescent ink on soft and flexible substrates.

Printing Electroluminescent Ink on Paper and PET

Aluminium PCBs - G4 LED bulbs in different Sizes, and Shapes

This technical guide examines aluminum PCB architecture, manufacturing processes, thermal characteristics, and implementation methodologies for optimal thermal performance in high-power electronic systems.

Aluminum PCB Design: Advanced Thermal Management Solutions for High-Power Electronics

<p dir="ltr">Bioelectronics is a multidisciplinary field that combines biology and electronics to develop devices that interface with biological systems. It plays a crucial role in the healthcare industry as it enables innovations like advanced prosthetics, electronic skins (e-skins), and exoskeletons to improve the quality of life for individuals by restoring or enhancing bodily functions. This integration of biological systems with electronic devices is transforming healthcare by allowing for more personalized, efficient, and responsive treatments.</p><h2 dir="ltr">The Evolution of Bioelectronics</h2><h3 dir="ltr">From Concept to Application</h3><p dir="ltr">Bioelectronics emerged in the late 18th century with Luigi Galvani's experiments, which discovered that electricity could stimulate muscles, introducing the concept of "animal electricity." His work laid the foundation for understanding neuroelectricity. In the 1930s, electrical stimulation research led to the development of cochlear implants. The field gained momentum in the 1940s and 1950s when Alan Hodgkin and Andrew Huxley recorded action potentials in nerve cells, earning them a Nobel Prize in 1963.&nbsp;1</p><p dir="ltr">Currently, bioelectronics in medicine is considered to be a rapidly growing market.&nbsp;1&nbsp;Bioelectronics is currently being applied in various areas of healthcare, including wearable devices, implantable sensors, neural interfaces, and drug delivery systems. For instance, wearable electronics like health monitors and smart textiles are used to track vital signs in real time. Similarly, implantable devices, such as neural interfaces, facilitate direct communication between the brain and external devices.</p><h2 dir="ltr">Key Technologies in Bioelectronics</h2><p dir="ltr">The current state of bioelectronics became possible due to several advanced key technologies. For instance, flexible electronics technologies allow devices to conform to the body's contours to enhance user comfort and enable continuous monitoring. Sensors embedded within these systems can capture and relay physiological data. Similarly, biocompatible materials, like bioceramics, are compatible with the body and minimize adverse reactions.</p><p dir="ltr">Another important technology in this regard is additive manufacturing, specifically DIW, since it allows users to print electronic structures with biocompatible inks layer by layer with high precision, which helps develop complex biomedical devices tailored to individual patients.</p><h1 dir="ltr">Understanding Biocompatible Inks and Their Role in Bioelectronics</h1><h3 dir="ltr">What Are Biocompatible Inks?</h3><p dir="ltr">Biocompatible inks are specialized materials designed for safe interaction with biological systems which makes them significant in developing bioelectronics. These inks are typically composed of polymers, hydrogels, conductive materials like gold and silver-silver chloride, or other bio-friendly substances that can mimic the properties of living tissues, such as flexibility and conductivity. The primary role of biocompatible inks in bioelectronics is to create interfaces that can integrate smoothly with biological tissues, enabling innovations like flexible sensors, and implantable devices.</p><h3 dir="ltr">Biocompatible Inks in DIW Systems</h3><p dir="ltr">DIW technology is an advanced additive manufacturing method used to print electrical circuits, features, patterns, and traces by extruding ink from a fine nozzle in a precise and controlled manner. DIW can print biocompatible inks onto biocompatible substrates for in- or on-body monitoring and recording of bioelectric signals.&nbsp;</p><p dir="ltr">Moreover, DIW offers high precision and flexibility, making it ideal for creating customized biomedical solutions as it allows the users to tune various parameters, including extrusion pressure, nozzle speed, and material calibration, to tailor the printed material's properties to the specific needs of a patient.</p><h3 dir="ltr">Compatibility with Common Substrates</h3><p dir="ltr">DIW systems are highly versatile and allow precise dispensing of various materials with differing mechanical and electrochemical properties. This adaptability makes DIW well-suited for printing onto organic polymer substrates like PEDOT:PSS, which is a combination of two distinct polymers (poly(3,4-ethylenedioxythiophene) and polystyrene sulfonate).&nbsp;</p><p dir="ltr">PEDOT:PSS offers excellent electrical conductivity, flexibility, and biocompatibility, making it an ideal substrate for biosensing applications. This compatibility of PEDOT:PSS with DIW helps create complex, multifunctional devices where the electrochemical behavior of this substrate enhances the functionality of printed sensors, leading to innovative biomedical solutions.</p><h1 dir="ltr">On-Body and In-Body Bioelectronics: Current Applications and Future Prospects</h1><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMwOTg0OTIxMDA0LUdvbGQgZWxlY3Ryb2RlIG9uIHNraW5fMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Over the next decade, the bioelectronic technologies market is expected to witness significant growth, projected to expand from $23.9 billion in 2024 to approximately $33.6 billion by 2029, achieving a compound annual growth rate (CAGR) of 7.0%. This growth is expected due to the rising elderly population and increasing prevalence of cardiovascular and neurological disorders. Non-invasive electroceutical devices, such as on-body bioelectronics like transcutaneous electrical nerve stimulation (TENS) devices, and in-body bioelectronics like implantable neurostimulators, are anticipated to grow at the highest rate, driven by advancements in technology and increased research and development investments. 2</p><h2 dir="ltr">On-Body Bioelectronics</h2><p dir="ltr">On-body bioelectronics refers to electronic devices and systems that are designed to be worn directly on the skin or embedded into wearable materials to monitor, stimulate, or interact with biological processes in the human body. Wearable devices like smartwatches and fitness trackers that monitor heart rate, body temperature, and other vital signs in real time are among the most common applications of on-body bioelectronics. Similarly, smart textiles are another type of on-body bioelectronics that include fabrics integrated with electronic components that can measure biomechanical movements, making them advantageous in sports, rehabilitation, and clinical monitoring.</p><h2 dir="ltr">In-Body Bioelectronics</h2><p dir="ltr">In-body bioelectronics, like pacemakers, cochlear implants, and neural interfaces, are implanted or inserted within the human body to monitor physiological processes, deliver therapies, or interact with biological tissues at a deeper level. For instance, neural interfaces enable direct communication between the brain and external devices, providing a unique approach to treating conditions like Parkinson's disease and epilepsy.&nbsp;</p><h2 dir="ltr">Multifunctional Bioelectronics</h2><p dir="ltr">Multifunctional bioelectronics aims to combine several functions, such as drug delivery, diagnostics, and therapeutic interventions, into a single device, enhancing their biomedical applications. For instance, silk-based transient bioelectronics, powered by triboelectric nanogenerators (TENGs) enable real-time in vivo monitoring and therapeutic treatments. These systems are self-powered and biodegradable, with adjustable lifespans and sensitivity through silk molecular customization.&nbsp;3&nbsp;These multifunctional devices have the potential to revolutionize personalized medicine by providing more comprehensive health solutions.</p><h2 dir="ltr">Challenges&nbsp;</h2><p dir="ltr">Integrating bioelectronics into healthcare presents significant inherent regulatory and ethical challenges. As bioelectronic devices are advancing, especially those used in the medical industry like pacemakers and neural implants, the impact on users' health means that regulatory and ethical considerations are increasing in importance.</p><p dir="ltr">Ensuring the safety and efficacy of these devices requires rigorous testing and compliance with regulatory standards. Ethical considerations also arise regarding user privacy, data security, and informed consent, especially when sensitive health information is collected and shared. Addressing these challenges is crucial to building public trust and ensuring the responsible use of bioelectronics.</p><p dir="ltr">Moreover, although on-body bioelectronics are beneficial, there are also challenges in developing on-body bioelectronics, particularly regarding power supply, and user comfort. These challenges require innovative solutions, and some solutions, like <a href="https://www.voltera.io/application-whitepapers/printing-magnesium-zinc-battery-saral-inks-pet?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=mg-zn-battery-white-paper">flexible batteries</a>, have already made significant differences in tackling some of these challenges.</p><p dir="ltr">Biocompatibility is another key challenge in developing in-body bioelectronics as these devices are placed inside the body; they must be made from compatible materials that do not provoke immune responses and can operate without causing harm to surrounding tissues. Moreover, maintaining the device's functionality over time, despite the harsh environment within the body, which includes exposure to fluids, enzymes, and mechanical stresses, is also a significant challenge.</p><h2 dir="ltr">Opportunities and Emerging Trends: The Future of Bioelectronics</h2><p dir="ltr">Currently, one of the most compelling emerging trends in bioelectronics is the development of smart bioinks. These bioinks have enhanced functionalities, such as responding to environmental changes like temperature, pH, and chemical stimuli. For instance, smart bioinks can be designed to release therapeutic agents in response to specific stimuli, promoting targeted healing and enhancing treatment efficacy.&nbsp;4&nbsp;This adaptability of smart bioinks can lead to future bioelectronic devices that dynamically adjust to the body's needs, further improving their therapeutic potential.</p><h1 dir="ltr">Voltera's Role in Advancing Bioelectronics and Biocompatible Inks</h1><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/zsniZR1if1s?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;" data-gtm-yt-inspected-24="true" id="654705223" title="Printing ECG Electrodes with Gold Ink on Voltera NOVA"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span><a href="https://www.wevolver.com/profile/voltera">Voltera</a> is a leading provider of advanced materials dispensing solutions for printing bioelectronics prototypes. Voltera's <a href="https://www.voltera.io/nova?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=nova-lp">NOVA</a> supports a wide range of materials, allowing researchers to test and experiment with various substrates and conductive inks. This flexibility allows innovation in bioelectronics, offering opportunities for breakthroughs in multifunctional bioelectronics devices. For instance, NOVA enables researchers to print biocompatible inks, such as gold and silver-silver chloride with exceptional precision to facilitate prototyping complex bioelectronics. This advanced system supports the development of traditional rigid electronics, as well as flexible hybrid electronics (flexible, stretchable, and conformable).&nbsp;</p><p dir="ltr">In particular, with a minimum line width of 100 µm and temperature-controlled dispensing, NOVA enables users to dispense biocompatible inks, pastes, gels, and adhesives on stretchable, soft, and flexible substrates, unlocking the ability to print bioelectronics that conform to the body’s natural contours.</p><h2 dir="ltr">Supporting Research and Innovation</h2><p dir="ltr">Researchers worldwide are using Voltera's tools to push the boundaries of bioelectronics. For example, in a 2024 <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">study</a>, researchers utilized the Voltera’s NOVA PCB printer to fabricate organic electrochemical transistors (OECTs) as part of their investigation into electrochemical organic neuromorphic devices (ENODes). NOVA was employed to directly print transistors with specific PEDOT formulations onto glass substrates, enabling the precise patterning of silver feedlines and contact pads. The team achieved a compact design with a high degree of control over the devices' channel and gate structures, facilitating the integration of biocompatible gel-electrolytes. This method allowed the study to examine ENODe performance under varied electrolyte conditions, specifically focusing on short- and long-term plasticity for potential applications in brain-chip interfacing.5</p><p dir="ltr">Similarly, in another 2022 <a href="https://doi.org/10.1109/FLEPS53764.2022.9781535">study</a>, researchers utilized Voltera's NOVA to fabricate silver-based tattoo electrodes to monitor bioelectric signals. NOVA enabled precise extrusion printing of high-viscosity silver flake ink on porous tattoo paper, leading to electrodes with lower sheet resistance and better electrical performance compared to inkjet-printed alternatives. This improved efficiency by minimizing ink absorption into the substrate, and reducing impedance in bioelectrical measurements.&nbsp;6</p><p dir="ltr">These researches, along with many others, are a testament to Voltera's commitment to supporting the next generation of bioelectronic innovations. Voltera's products, like NOVA and V-One, ensure that the next generation of devices continues to improve the quality of life for patients worldwide.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">The importance of bioelectronics is self-evident, as these technologies have immense significance in advancing modern personalized medicine, real-time health monitoring, and patient outcomes, which ultimately have the potential to revolutionize the future of medicine. DIW technology is integral to these advancement as it enables precise prototyping of bioelectronic devices with biocompatible inks in both on-body and in-body applications.&nbsp;</p><p dir="ltr">The projected market growth of bioelectronics is up to $33.6 billion by 2029, which indicates that this field is rapidly advancing and holds immense potential to reshape the future of healthcare.</p><h2 dir="ltr">Explore the future of bioelectronics applications&nbsp;</h2><p dir="ltr">For researchers and engineers looking to explore the next frontier of bioelectronics, Voltera's platforms provide the tools and support necessary to advance the field. <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=book-a-meeting">Book a call with Voltera</a> to learn how their technology can contribute to <a href="https://www.voltera.io/applications/bioelectronics?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=bioelectronics-application-page">your bioelectronics applications</a>.</p><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr">Stavrinidou, E., &amp; Proctor, C. M. (Eds.). (2022). Introduction to Bioelectronics: Materials, Devices, and Applications. AIP Publishing LLC. <a href="https://doi.org/10.1063/9780735424470_001">https://doi.org/10.1063/9780735424470_001</a></p></li><li dir="ltr"><p dir="ltr">Electroceuticals/Bioelectric Medicine Market worth $33.6 billion by 2029. [Online] Markets and Markets. Available at: <a href="https://www.marketsandmarkets.com/PressReleases/electroceutical.asp">https://www.marketsandmarkets.com/PressReleases/electroceutical.asp</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">Zhang, Y., Zhou, Z., Fan, Z., Zhang, S., Zheng, F., Liu, K., ... &amp; Tao, T. H. (2018). Self‐powered multifunctional transient bioelectronics. Small. <a href="https://doi.org/10.1002/smll.201802050">https://doi.org/10.1002/smll.201802050</a></p></li><li dir="ltr"><p dir="ltr">Maan, Z., Masri, N. Z., &amp; Willerth, S. M. (2022). Smart bioinks for the printing of human tissue models. Biomolecules. <a href="https://doi.org/10.3390/biom12010141">https://doi.org/10.3390/biom12010141</a></p></li><li dir="ltr"><p dir="ltr">Rana, D., Kim, C. H., Wang, M., Cicoira, F., &amp; Santoro, F. (2024). Tissue-like interfacing of planar electrochemical organic neuromorphic devices. Neuromorphic Computing and Engineering. <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta</a></p></li><li dir="ltr"><p dir="ltr">El-Hajj, Y., Ghalamboran, M., &amp; Grau, G. (2022, July). Inkjet and extrusion printed silver biomedical tattoo electrodes. In 2022 IEEE International Conference on Flexible and Printable Sensors and Systems (FLEPS) IEEE. <a href="https://doi.org/10.1109/FLEPS53764.2022.9781535">https://doi.org/10.1109/FLEPS53764.2022.9781535</a></p></li><li dir="ltr"><p dir="ltr">Voltera [Online] Wevolver, Available at: <a href="https://www.wevolver.com/profile/voltera">https://www.wevolver.com/profile/voltera</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">NOVA. The future of printed electronics [Online] Voltera, Available at: <a href="https://www.voltera.io/nova">https://www.voltera.io/nova</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">V-One. PCB prototyping made easy [Online] Voltera, Available at: <a href="https://www.voltera.io/v-one">https://www.voltera.io/v-one</a> (Accessed on September 4, 2024)</p></li></ol>

This article explores the role of biocompatible inks in bioelectronics, particularly within Direct Ink Writing (DIW) systems and forecasts future trends and challenges in on-body and in-body bioelectronic technologies over the next decade.

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