This article delves into the fundamentals of EMI gaskets, types, and their critical role in protecting electronic devices and ensuring optimal performance in various engineering applications.

EMI Gaskets: The Unsung Heroes of Electromagnetic Interference Shielding

This article delves into the various types of printed circuit boards, their fundamental concepts, structures, manufacturing processes, and advanced PCB technologies, highlighting their advantages, limitations, and typical applications.

Types of Printed Circuit Boards: A Comprehensive Guide

For engineers working on soft robotics or wearable devices, keeping things light is a constant challenge: heavier materials require more energy to move around, and – in the case of wearables or prostheses – cause discomfort. Elastomers are synthetic polymers that can be manufactured with a range of mechanical properties, from stiff to stretchy, making them a popular material for such applications. But manufacturing elastomers that can be shaped into complex 3D structures that go from rigid to rubbery has been unfeasible until now.“Elastomers are usually cast so that their composition cannot be changed in all three dimensions over short length scales. To overcome this problem, we developed DNGEs: 3D-printable double network granular elastomers that can vary their mechanical properties to an unprecedented degree,” says Esther Amstad, head of the <a href="https://www.epfl.ch/labs/smal/" target="_blank">Soft Materials Laboratory</a> in EPFL’s School of Engineering.Eva Baur, a PhD student in Amstad’s lab, used DNGEs to print a prototype ‘finger’, complete with rigid ‘bones’ surrounded by flexible ‘flesh’. The finger was printed to deform in a pre-defined way, demonstrating the technology’s potential to manufacture devices that are sufficiently supple to bend and stretch, while remaining firm enough to manipulate objects.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713431737943-2048x1152.jpg" style="width: 100%px;" class="fr-fic fr-dib">The lab's DNGE prototype ‘finger’ with rigid ‘bones’ surrounded by flexible ‘flesh’ © Adrian AlberolaWith these advantages, the researchers believe that DNGEs could facilitate the design of soft actuators, sensors, and wearables free of heavy, bulky mechanical joints. The research has been published in the journal <a href="https://onlinelibrary.wiley.com/doi/10.1002/adma.202313189" target="_blank" rel="noopener">Advanced Materials</a>.<h2>Two elastomeric networks; twice as versatile</h2>The key to the DNGEs’ versatility lies in engineering two elastomeric networks. First, elastomer microparticles are produced from oil-in-water emulsion drops. These microparticles are placed in a precursor solution, where they absorb elastomer compounds and swell up. The swollen microparticles are then used to make a 3D printable ink, which is loaded into a bioprinter to create a desired structure. The precursor is polymerized within the 3D-printed structure, creating a second elastomeric network that rigidifies the entire object.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713431770492-3840x2159+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib">Example of DNGEs (3D-printable double network granular elastomers) © Titouan VeuilletWhile the composition of the first network determines the structure’s stiffness, the second determines its fracture toughness, meaning that the two networks can be fine-tuned independently to achieve a combination of stiffness, toughness, and fatigue resistance. The use of elastomers over hydrogels – the material used in state-of-the-art approaches – has the added advantage of creating structures that are water-free, making them more stable over time. To top it off, DNGEs can be printed using commercially available 3D printers.“The beauty of our approach is that anyone with a standard bioprinter can use it,” Amstad emphasizes.One exciting potential application of DNGEs is in devices for motion-guided rehabilitation, where the ability to support movement in one direction while restricting it in another could be highly useful. Further development of DNGE technology could result in prosthetics, or even motion guides to assist surgeons. Sensing remote movements, for example in robot-assisted crop harvesting or underwater exploration, is another area of application.Amstad says that the Soft Materials Lab is already working on the next steps toward developing such applications by integrating active elements – such as responsive materials and electrical connections – into DNGE structures.<hr>ReferencesE. Baur, B. Tiberghien, E. Amstad, 3D Printing of Double Network Granular Elastomers with Locally Varying Mechanical Properties. Adv. Mater. 2024, 2313189.&nbsp;<a href="https://doi.org/10.1002/adma.202313189" target="_blank" rel="noopener">https://doi.org/10.1002/adma.202313189</a>

Example of DNGEs (3D-printable double network granular elastomers) © Titouan Veuillet

EPFL researchers are targeting the next generation of soft actuators and robots with an elastomer-based ink for 3D printing objects with locally changing mechanical properties, eliminating the need for cumbersome mechanical joints.

An ink for 3D-printing flexible devices without mechanical joints

Is there anything better than a good cup of coffee? It's devine when it's hot, and deliciously refreshing when it's iced.&nbsp;…But room-temperature coffee? Not so great.&nbsp;For most adults around the world, brewing a hot cup of coffee is an established part of our morning routine. But when you have a busy day, it’s easy to get preoccupied and neglect your coffee until it cools to an unpleasant temperature.Duru Uluk, a Voltera test engineering intern, set out to find a solution to this problem. Her goal was to create an induction mug heater using in-mold electronics (also known as in-mold structural electronics).In-mold electronics (IME) processes involve printing conductive inks on moldable plastic films, which are then formed into a desired 3D shape. In the full IME process, after thermoforming, the part is passed along to injection molding, where it is molded in plastic and the electronics become part of the entire structure.&nbsp;In IME, the electronics are printed using a standard process of screen-printing traces onto thermoformable plastics, but new innovative materials — like specially formulated functional inks optimized for high single-stretch operation — allow the traces to stretch into the new thermoformed shape and maintain conductivity.&nbsp;This technology is particularly exciting for automotive and aerospace applications, where thousands of feet of copper wire could be replaced with conductive traces integrated directly into the vehicle’s panels to reduce the vehicle’s weight and improve efficiency. Incorporating IME into vehicle construction also presents opportunities for new design concepts, features, and functionality — like the ability to incorporate strain sensors directly into panels to monitor for damage, interactive surfaces in the interior vehicle panels, or to heat and de-ice the wing of an airplane during flight.&nbsp;In the image below, all the red components identify the wire in a vehicle:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283732859-63b49367152a021e60088642_3ZoHWv-Zic4V11X_3xOkWv831wmyc-hbLHIuslxurYTiXj6bsTy7zNxC97dVW-rYkGLgtJeYYhR5KCm91dpma-EpW2wOgcFG4d_InqrlcJFlFDp3zdS57GulmRe_iM-7DsUkP7ZUhs4RA1FXQ5HbMhmn9_Hgoqkd0BlsUhtZOuHgArS5v-Nn0GG6gaZX3.png" style="width: 100%px;" class="fr-fic fr-dib"><ul id="isPasted"><li>One vehicle has 5000 feet of wires = 50 lbs of copper.</li><li>Transporting 50 lbs burns 12 L of gas per year.</li><li>70,000,000 new cars produced per year.</li><li>840,000,000 L of gas is burned to transport copper cables per year.</li></ul>‍In addition to this example of copper wire, IME offers plenty of other opportunities to reduce the mass of many vehicle components, like the headlight assembly, dashboard, center console, and more.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283763549-63b49367f5596f24c741daec_4ZpHDUtkWx5wmeYtb6X6YjGlsuiVxdPXJ3H64MFHHtiDpTG1Bil6Mat9evncEvLP-DsCX7T2TC63nZtB5DzKQI8Vs98V-vE0R6e3Xbh6oy2iLiPHV6t7InCwE-C3-Mv_9XaLvGjKOrAfnppvIszjmAkMSYyGpSKIKpmn1A621NCHPe04dRGFy75i-Om81.png" style="width: 100%px;" class="fr-fic fr-dib"><a href="https://www.idtechex.com/en/research-article/what-does-2023-hold-for-printed-flexible-electronics/28172" target="_blank" id="isPasted">IDTechEx</a> anticipates the mainstream adoption of in-mold electronics in automotive interiors to begin in 2023, and is forecasting that electronics will be printed onto 3D surfaces, like door panels, in 2026.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283778550-63b49367684ec45971bc70ac_9Gf654z1WMdopCZ5ZMfeK0mO-ZCYnQ1bpkpRVMCY4A4crd2KzqLzh6pao8OoT3ACsO7xnDTdqSfhdTUkRLs-flCOWGlTTjWUHQElpJ__YKFBoiHltw43eQPxsSzSt6DFJUnZ7ONaolf9Fv32CugpbDAMtWnRMf7bRfl-XDBMCBhXX--1QKBBwFR8jUAWd.png" style="width: 100%px;" class="fr-fic fr-dib">Roadmap for selected emerging printed/flexible electronics technologies. Source: IDTechExBut let’s get back to Duru’s coffee conundrum.&nbsp;Using&nbsp;<a href="http://voltera.io/nova" target="_blank">NOVA</a>, a&nbsp;<a href="https://mayku.me/formbox" target="_blank">Mayku Formbox</a>, and a&nbsp;<a href="https://formlabs.com/3d-printers/form-2/" target="_blank">Formlabs 3D printer</a>, Duru designed and built a mug heater with in-mold electronics technology.&nbsp;“During my co-op term at Voltera, Matt (Ewertowski, Product Manager) was my supervisor and also just a super cool person to talk to. We had conversations about different applications of NOVA and how flexible substrates open doors to a lot of different project ideas,” Duru recalled. “He suggested the idea of using the Mayku Formbox alongside NOVA for an in-mold electronics project. I did some research about making molds, molded electronic applications, and coil heaters — and from there it seemed feasible enough to continue with a demo.”&nbsp;So, Duru got to work. First, she used the Formlabs Form 2 3D printer to create a resin mold, and then used NOVA to print traces onto the Mayku Formbox substrates. Finding the optimal baking temperature for the Mayku substrates was a bit of a challenge, since they aren’t intended for IME, but with some experimentation and a bit of help from Mayku, she eventually found the right temperature and baking time to avoid substrate deformation. Once the curing temperature was refined, Duru encountered trace breakage during the forming process. Through some trial and error, Duru refined the design of the mold and the traces until she was successful in creating a design that could be thermoformed and maintain conductivity.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283802120-63b49367bedfeccaa9cf2122_18Qk-iwOjIp00g_snsqEE-x33qu6yTIyGZgI7LuwCgRcaZM_MqpFYbKCYiJuFZBouwEXx12yQES8yTL8EyCsHTZdx9tJe3hHoxa_25BT4I0v1AKIbJnATzxzcMlx7Sax3lK_uGQrK_F9idp-Fxa-5rsh0MAJA5HS_IV8y-YJOUrY7bGJacjQY-0kMgNi_.png" style="width: 100%px;" class="fr-fic fr-dib">“It took several iterations to achieve a design that ensured a fully conductive trace with no breaks. When the baked print goes into the Mayku Formbox, the substrate is being heated and deformed,” she explained. “There are so many factors to consider. Will the conductive ink be damaged? Will the substrate be damaged? That required a lot of correspondence with people to get information about melting points and what not, including <a href="https://insulectro.com/" target="_blank" id="isPasted">Insulectro</a>, who supplied us with the ink — they really helped out. But the biggest issue was of course the sharp angle of the mold, causing the trace to be deformed to a point where it is no longer conductive. And that’s why I had to gradually reduce that angle and on the trace edges.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283815611-63b493679710e828f9389688_waXyaVYzojKJhCnZk3L-4449I7fgizrTBOeX5J_OFFrewsSraWdgajH_SZWHidk2TmHiCQQyixG-GXwRC5MjWiTqBm1HuSU0SPIVCTu_nf4hCdQgQfHpeLhQ5nWupJ7h9OA6rmDnQfC3-dykkJzPrYl_hx-uljy8UhHay90NQDdw1DOL--90k-rxEUl0.jpeg" style="width: 100%px;" class="fr-fic fr-dib">Despite the challenges of the project, Duru loved working with <a href="https://www.youtube.com/watch?v=T62cUY8uj8M" target="_blank" id="isPasted">NOVA</a>. “Everyday I was excited to use the NOVA just because of how cool it is. The user interface is super easy to use, the modular design and the way everything magnetically clicked into place, the sounds, the lights, etc.” she noted. “I also love NOVA’s ability to work with various substrates. I worked a lot with flexible substrates during my time at Voltera, so the vacuum feature was being used frequently.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283834936-63b4936799db03ad4a1aacaf_ZS6BCi4fHe5wPMhX5X845YVFQK8foJ0C90XCCX2Q0EIZFQ_TL2AX2fVH2gvyMzbL3mfu1mFjlED5rciLDX-kYKeIIYwMn4lQYjsoLvpLbzf2P3dVsHL8YTW0Qjss0gFxsrC5DuwivgbeDPpdGys4vfyDzQ2fmShgr4FPqtWeknJUgW3gxonzz5EeLXoV.jpeg" style="width: 100%px;" class="fr-fic fr-dib">In Duru’s eyes, there are so many exciting applications for the technology. “In biomedical applications, for example, you could use in-mold electronics to build medical tools or prosthetics that are ergonomic and accessible, with electronic components integrated through in-mold processes — to easily incorporate electronics into things that have awkward shapes, or have been challenging to design using traditional methods. And in cases like these, being able to use NOVA to build electronics that fit a specific, custom shape may be a great advantage.”&nbsp;The experience of working with NOVA was inspiring for Duru, and piqued her interest in electronics innovation. “During my time working with NOVA I gained a big interest in additive electronics and learned a foundation of knowledge (about conductive inks, substrates, rheology) that I still bring up at every chance I get,” she said. “I also got inspired to tinker more. Having access to benchtop tools like the NOVA would enable people to tinker freely and try new things — which is beneficial to the engineering iteration process.”&nbsp;Working at Voltera also impacted Duru’s career aspirations. “Many of my co-op placements have been R&amp;D specific. During my future career I think I’d like to work in spaces where I have access to tools like NOVA while doing R&amp;D work and product development. My perspective has shifted to appreciate the potential of additive electronics in&nbsp;<a href="https://www.researchgate.net/publication/361717600_Inkjet_and_Extrusion_Printed_Silver_Biomedical_Tattoo_Electrodes" target="_blank">biomedical applications</a> — for example the&nbsp;<a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/633c55566e5bffe8db61ba27_NOVA-0082%20-%20Insole%20Case%20Study_v2.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">in-sole pressure sensor</a> project I did, or things like wearable biomarker sensors.”And now, thanks to her in-mold mug heater, Duru can iterate for hours and never have to worry about her coffee getting cold.&nbsp;

Duru Uluk, a Voltera test engineering intern, created an induction mug heater using in-mold electronics (also known as in-mold structural electronics).

Warming Your Coffee with In-Mold Structural Electronics

This comprehensive series delves into the fundamentals of PCB design, including design workflow, signal integrity, manufacturing, testing and debugging, advanced design techniques, and the latest software and tools available for PCB design.

PCB Design: A Comprehensive Guide to Printed Circuit Board Design - Part 2

PCB Design: A Comprehensive Guide to Printed Circuit Board Design - Part 1

The TechBlick Innovations Festival, happening online on April 25, 2024, is a curated event for engineers, researchers, entrepreneurs, and inventors, focusing on advancements in additive, printed, 3D, and wearable electronics, among other topics.&nbsp;It features networking opportunities and an immersive virtual exhibition. Attendees can expect talks from leading global speakers representing companies like SPGPrints, ACI Materials, and Akoneer, covering topics such as scaling printed electronics from lab to production, transformative conductive inks, and semiconductor packaging innovations. For more details, <a href="https://wevlv.co/techblick24eventdetails" target="_blank" rel="noopener noreferrer">visit the event page</a><a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank" rel="noopener noreferrer"></a><a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank" rel="noopener noreferrer">.</a>The last Innovation event had over 700+ participants [not registrants]! Do not miss this opportunity! There are simultaneous events throughout the day, including presentations from Neibling, NanoPrintek, TracXon, Kimoto, and more.&nbsp;The cutting-edge virtual environment enables you to meet other participants, attend events, and discover new technologies.&nbsp;<a href="https://wevlv.co/techblick_innovation_24" target="_blank" rel="noopener noreferrer" class="button-main-action">Register now!</a><h2 dir="ltr" id="isPasted">Speaker Highlights</h2>The event features a wide range of speakers covering all aspects of the additive and flexible electronics sector. Following are some of the highlights of notable speakers and their topics from Track 1 and Track 2:<h3 dir="ltr">Highlights from Track 1</h3>Innovating with TFT technology in both optoelectronic and biological ways — Partner and Co-CEO of LinkZill,Yixing Yang, will speak about TFT semiconductor technology and its applications in various fields of optoelectronics and life sciences such as large-area bio-sensing, novel display, high-throughput DNA synthesis, and in-vitro diagnostics (IVD).Scalable, customizable, multimodal electrode platform for biosensors and sensors — Healthcare Marketing Director of Linxens,&nbsp;Christelle Robellin, will speak about the latest advancements in Point-of-Care Diagnostics enabled by Linden’s innovative manufacturing process. She will cover recent developments in electrode design, surface coating, microfluidics, and connectivity, highlighting their applications in continuous monitoring of glucose, wound healing, water quality, and sports performance.Advances in wash testing of conductive inks for wearable electronics — Business Development Manager of Nagase ChemteX America Corporation (NCU),Alan Brown, will address the significant challenges faced by conductive inks when applied in wearable applications, with a particular focus on washability—the most formidable obstacle among them.&nbsp;Beyond paper: Inkjet printing is the future in drops — Manager of Sales and Services of Suss MicroTec,&nbsp;Peter de Vrieze, will discuss groundbreaking technologies aimed at advancing the field of printed electronics. De Vrieze will spotlight the latest advancements in analysis tools, ranging from cutting-edge dropwatching technologies to intelligent inspection tools.<h3 dir="ltr">Highlights from Track 2</h3>Demonstration of flexible and printed electronics production using INO PE Line A7 — representing INO Sales US,Nivas Vehar will demonstrate the production process of flexible and printed electronics through three-color screen printing, showcasing zero scrap and exceptional efficiency. After the demonstration, attendees can engage in a Q&amp;A session to explore the complexities of this cutting-edge process.Going maskless for semiconductor packaging with SSAIL — CCO of AkoneerTadas Kildusis, will introduce SSAIL technology, enabling direct copper deposition onto organic and dielectric materials. He'll discuss its applications in RDL, fanouts, and heterogeneous integration, emphasizing high adhesion for reliability in automotive and defense.Laser Patterning of sputtered coatings for high-volume production of flexible devices — Mechanical Engineer at Intellivation LLC,Matthew Kleyn, will discuss advanced roll-to-roll (R2R) solutions using vacuum coatings and laser patterning to meet the demand for high-volume flexible devices across industries. He'll emphasize optimized process controls and the importance of modularity and scalability for high-volume production.High Pressure Forming (HPF) for In-Mold Electronics (IME) processes — Director Sales &amp; Marketing at Niebling GmBH,Udo Weustenhagen, will speak about the importance of precise 3D substrate forming for In-Mold Electronics (IME). He will cover the alignment of conductor tracks, electronic components, and graphics within injection tool cavities. Weustenhagen will introduce the high-pressure forming process, highlighting its benefits over traditional methods, including lower temperatures and clever automation for series production.For the full list of speakers and presentation times, <a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank">visit the event page.</a>

Engineers, researchers, entrepreneurs, inventors, and end users are invited to join TechBlick Innovations Festival, exploring additive, printed, 3D, and wearable electronics on 25 April 2024 online.

TechBlick Innovations Festival

This article provides a detailed understanding of microprocessor vs integrated circuit, their basics, key differences, future trends, challenges, and how they synergize to form the backbone of our digital systems.

Microprocessor vs Integrated Circuit: Unveiling the Core of Modern Technology

Small wearable or implantable electronics could help monitor our health, diagnose diseases, and provide opportunities for improved, autonomous treatments. But to do this without aggravating or damaging the cells around them, these electronics will need to not only bend and stretch with our tissues as they move, but also be soft enough that they will not scratch and damage tissues.Researchers at Stanford have been working on skin-like, stretchable electronic devices for over a decade. In a paper published March 13 in Nature, they present a new design and fabrication process for skin-like integrated circuits that are five times smaller and operate at one thousand times higher speeds than earlier versions. The researchers demonstrated that their soft integrated circuits are now able to drive a micro-LED screen and detect a braille array that is more sensitive than human fingertips.“We’ve made a significant leap forward. For the first time, stretchable integrated circuits are now small enough and fast enough for many applications,” said <a href="https://mandrillapp.com/track/click/30855492/profiles.stanford.edu?p=eyJzIjoiOVAtVVZYVEltMTAyQXVpZ2ppSmFNd3RkQjNvIiwidiI6MSwicCI6IntcInVcIjozMDg1NTQ5MixcInZcIjoxLFwidXJsXCI6XCJodHRwczpcXFwvXFxcL3Byb2ZpbGVzLnN0YW5mb3JkLmVkdVxcXC96aGVuYW4tYmFvXCIsXCJpZFwiOlwiMGM2YWMxYWU5MTg4NGZjYWFjMzI1ZDc2M2MyZDhhODdcIixcInVybF9pZHNcIjpbXCJkMGY0ZGMxYjBmMDE3OTkzNjhmOGE4NzJlMmViNzQ3ZTFjZmNmMjBkXCJdfSJ9" data-extlink="" target="_blank">Zhenan Bao</a>, a K. K. Lee Professor in Chemical Engineering at Stanford and senior author on the paper. “We hope that this can make wearable sensors and implantable neural and gut probes more sensitive, operate more sensors, and potentially consume less power.”<h2>Flexible, stretchable, and functional</h2>The core of the circuits are stretchable transistors made from semiconducting carbon nanotubes and soft elastic electronic materials developed in Bao’s lab. Unlike silicon, which is hard and brittle, the carbon nanotubes sandwiched between elastic materials have a fishnet-like structure that allows them to continue to function while they stretch and deform. The transistors and circuits are patterned onto a stretchable substrate, along with stretchable semiconductor, conductor, and dielectric material.“This is many years of material and engineering development,” Bao said. “We not only needed to develop new materials, but we also needed to develop the circuit design and the fabrication process to make the circuits. There are many layers stacked together and if one layer doesn’t work, we have to restart everything from scratch.”In one demonstration of their new stretchable electronics design, the researchers were able to fit more than 2,500 sensors and transistors into a square centimeter, creating an active-matrix tactile array over ten times more sensitive than human fingertips. The researchers showed that the sensor array can detect the locations and orientation of tiny shapes or recognize whole words in Braille.“With Braille, you usually sense one letter at a time,” said <a href="https://mandrillapp.com/track/click/30855492/baogroup.stanford.edu?p=eyJzIjoiQWFWMU9jM2VqYXZMR2g5TFVfMnRPcTE4cGxnIiwidiI6MSwicCI6IntcInVcIjozMDg1NTQ5MixcInZcIjoxLFwidXJsXCI6XCJodHRwczpcXFwvXFxcL2Jhb2dyb3VwLnN0YW5mb3JkLmVkdVxcXC9wZW9wbGVcXFwvZG9uZ2xhaS16aG9uZ1wiLFwiaWRcIjpcIjBjNmFjMWFlOTE4ODRmY2FhYzMyNWQ3NjNjMmQ4YTg3XCIsXCJ1cmxfaWRzXCI6W1wiNTgyODY0ZTdiMWU3NWU4ZGRiOWM5OWIyOTI5YWU1YTFiODU3MDZiYVwiXX0ifQ" data-extlink="" target="_blank">Donglai Zhong</a>, a postdoctoral researcher in Bao’s lab and co-first author on the paper. “With such a high resolution, you could sense a whole word, or potentially a whole sentence, with just one touch.”The researchers also used their stretchable circuits to drive a micro-LED display with a refresh rate of 60 Hz, which is the typical refresh rate of a computer or TV screen. Previous versions of the stretchable circuits weren’t fast enough at small sizes to generate enough current to accomplish this.“We’re really excited about these performance improvements because they enable us to do a lot of new things,” said <a href="https://mandrillapp.com/track/click/30855492/baogroup.stanford.edu?p=eyJzIjoia1V0NTdYUFNUVGxncTZEZFg0RWh1MGRnRDg0IiwidiI6MSwicCI6IntcInVcIjozMDg1NTQ5MixcInZcIjoxLFwidXJsXCI6XCJodHRwczpcXFwvXFxcL2Jhb2dyb3VwLnN0YW5mb3JkLmVkdVxcXC9wZW9wbGVcXFwvY2FuLXd1XCIsXCJpZFwiOlwiMGM2YWMxYWU5MTg4NGZjYWFjMzI1ZDc2M2MyZDhhODdcIixcInVybF9pZHNcIjpbXCI4MTliZDk3YzY5NzMxMjg0ZjcwMDgwNTY4MDdhZjFjOGNlYmE0ZTExXCJdfSJ9" data-extlink="" target="_blank">Can Wu</a>, a postdoctoral researcher in Bao’s lab and co-first author on the paper. “Preliminary results demonstrate that our transistor can be used to drive commercial displays commonly used in computer monitors, for example. And for biomedical applications, a high-density, soft, and conformable sensing array could allow us to sense human body signals, such as from our brains and muscles, at a large scale and fine resolution. This could lead to next-generation brain-machine interfaces that are both high-performance and biocompatible.”<h2>Soft circuits for the future</h2>The researchers intentionally developed materials and processes that could work with existing fabrication tools, so that the circuits could make the jump to commercial manufacturing more easily. Their process relies on fabrication techniques similar to what is currently used for making display screens, although the materials involved are entirely different. Manufacturers wouldn’t be able to make these circuits without some additional fine-tuning, but the tools are already in place, Bao said.Of course, there are more hurdles before these stretchable and soft integrated circuits can be ready for commercialization. Body and tissue movement can still cause some variation in the electrical characteristics of the circuits – Bao and her colleagues are working on new designs that could reduce these effects – and the devices will need some sort of soft moisture protection before they can be put to use.“There are still challenges for the future of this technology, but these recent developments open up some very exciting biomedical applications for wearable and implantable electronics,” Bao said. “And it also has applications in soft robotics, giving robots a sensing functionality that approaches that of humans and makes them safer for people to work with.”Bao is a member of&nbsp;<a href="https://biox.stanford.edu/" data-extlink="" target="_blank">Stanford Bio-X</a>, the&nbsp;<a href="https://med.stanford.edu/cvi.html" data-extlink="" target="_blank">Stanford Cardiovascular Institute</a>, the&nbsp;<a href="https://humanperformance.stanford.edu/" data-extlink="" target="_blank">Wu Tsai Human Performance Alliance</a>, the&nbsp;<a href="https://neuroscience.stanford.edu/" data-extlink="" target="_blank">Wu Tsai Neurosciences Institute</a>, and the&nbsp;<a href="https://med.stanford.edu/mchri.html" data-extlink="" target="_blank">Maternal &amp; Child Health Research Institute</a>; an affiliate of the&nbsp;<a href="https://energy.stanford.edu/" data-extlink="" target="_blank">Precourt Institute for Energy</a>&nbsp;and the&nbsp;<a href="https://woods.stanford.edu/" data-extlink="" target="_blank">Stanford Woods Institute for the Environment</a>; and a faculty fellow of&nbsp;<a href="https://chemh.stanford.edu/" data-extlink="" target="_blank">Sarafan ChEM-H</a>. Bao is an investigator of CZ-Biohub-San Francisco and an innovation investigator of Arc Institute.Other Stanford co-authors of this research include research scientist Jeffrey B.-H. Tok; postdoctoral researchers Yuanwen Jiang (Co-first-author), Min-gu Kim, Chien-Chung Shih, Jian-Cheng La, Chuanzhen Zhao, Shiyuan Wei, Xiaozhou Ji, Yi-Xuan Wang, Chengyi Xu, Naoji Matsuhisa, Yusheng Lei, Deya Liu, Song Zhang, and Yuto Ochiai; and doctoral students Yujia Yuan, Yuya Nishio, Weichen Wang, Theodore Z. Gao, Yu Zheng, Zhiao Yu, Huaxin Gong, and Shuhan Liu.

Intrinsically stretchable transistors and integrated circuits under large deformation after being released from the supporting substrate. | Image courtesy of Donglai Zhong, Jiancheng Lai, and Yuya Nishio of the Bao Group

Stanford researchers have developed soft integrated circuits that are powerful enough to drive a micro-LED screen and small enough to read thousands of sensors in a single square centimeter.

Smaller, more powerful stretchable electronics for wearables and implantables

This article delves into the world of RF PCBs, exploring the design considerations that ensure signal integrity, the materials that minimize signal loss, and the intricate processes that bring these high-performance boards to life.

RF PCB: Design, Materials, and Manufacturing Processes

Behind the rise of many of today’s latest technologies, from wearable tech to the Internet of Things, are printed electronics. As we’ll explore throughout this article, these low-cost and highly versatile electronic devices, which can be made using existing printing processes like inkjet or screen printing, present a vast array of benefits and potential applications. We will also be taking a closer look at Canadian company <a href="https://hubs.ly/Q029xhJN0" target="_blank">Voltera</a> and how its additive printing technology for electronics is unlocking greater accessibility and innovation for printed electronic development.<h2 dir="ltr">Understanding Printed Electronics</h2>In general, the term printed electronics refers to all electronics that are manufactured by printing conductive and dielectric materials onto a substrate to create a circuit. This technique is not unlike two-dimensional printing on paper. In fact, many printed electronics are made using conventional printing techniques, like inkjet printing and screen printing. These technologies have been adapted to deposit inks embedded with conductive and dielectric materials, such as metals or carbon-based materials, onto rigid or flexible substrates, including paper, polymer films, and more.This approach differs from conventional electronic production methods, such as physical vapor deposition (PVD) and etching, which are both used in the production of printed circuit boards (PCBs). The PVD process, for instance, is a type of vacuum deposition that applies fine films and coatings to a substrate.[1] In the etching process, conductive material (usually copper) is selectively removed from a printed circuit board to create an electronic circuit.[2] While these processes are both more established than printed electronics, they are more limited in terms of design and flexibility, typically requiring the use of a rigid substrate and an enclosure. They are also more costly, requiring a steep investment in specialist equipment.Sustainability is another key consideration with conventional PCB production processes. PCB manufacturing is not only extremely energy intensive, it also generates hazardous waste, and consumes a significant amount of water (as much as “1.5m^3 for every m^2 of board processed”).[3] This translates to over one ton of water for every square meter of circuit board.&nbsp;Printed electronics and the processes used to make them are ever-evolving. For example, advances in material science are opening up more types of printable materials, including conductive inks that are engineered to be stretched while retaining their properties. The ability to print flexible conductive elements onto stretchable substrates is owed to developments in the field of nanotechnology. Specifically, the ability to produce and embed nanoparticles made from conductive or dielectric materials optimized for stretch and flexibility into a printable ink.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5ODAyMTg4MDEwLXZvbHRlcmEgMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">Benefits of Printed Electronics</h2>Printed electronics offer a number of advantages compared to more conventional electronics and create previously impossible opportunities. Among these benefits are design freedom, cost-effectiveness, and greater sustainability.<h3 dir="ltr">Design freedom</h3>One of the main advantages of printed electronics is the ability to realize a greater range of designs. Using printing technologies it is possible to print electronics on a larger surface area, as well as to design thinner sensors that can be seamlessly embedded into products. This includes very thin devices printed on flexible substrates, which can conform to a product’s surface. Unlike in rigid PCB design, where the circuit determines the form factor of the product, printed flexible electronics can be adapted to a specific shape, opening up opportunities for device design, compactness, and conformability.<h3 dir="ltr">Cost effective</h3>Printed electronics also have the benefit of being more affordable to produce than conventional electronics. This is due to a number of factors. First, the equipment required to print electronics is itself low cost compared to conventional PCB production methods. Second, it is possible to deposit conductive inks onto low-cost substrates, such as paper or plastic films, which are cheaper than PCB substrates, traditionally made from FR-4, a fiberglass and epoxy composite. Third, printed electronics are cost-effective even for small volumes, which makes the technology more accessible to small businesses and research labs with limited resources.<h3 dir="ltr">Sustainability</h3>Another distinct advantage of printed electronics is that they can have a smaller environmental impact. For one, the printing process involved in depositing inks onto a substrate consumes far less energy than conventional electronic production methods. From another perspective, manufacturers can choose to work with more sustainable materials, like water-based inks and biodegradable substrates. Conductive materials in inks can also be made from bio-based and biodegradable materials, like carbon-based particles, which reduce the need for critical raw materials like metals.[4]<h2 dir="ltr">Applications of Printed Electronics</h2>There are numerous current use cases for printed electronics and many potential applications as the technology continues to advance. Below are just a handful of examples of how printed electronics can be used.&nbsp;<h3 dir="ltr">IoT and Wearables</h3>Since printed electronics can be seamlessly integrated into small objects and onto flexible substrates, there is huge potential in IoT and wearables. Devices like keypads can benefit from thin electronic circuits, while wearable products like wristbands, shirts, and gloves can be embedded with flexible sensors that track anything from performance metrics to vitals.<h3 dir="ltr">Medical and Healthcare</h3>Wearable devices are also becoming more prevalent in medical settings, enabling healthcare professionals to print sensors on biocompatible substrates to monitor a range of <a href="https://www.voltera.io/blog/printed-tattoo-electrodes" target="_blank">patient vitals</a>, including heart rate, temperature, blood sugar, muscle movements, and more. This field of applications has the potential to be game-changing for remote diagnosis and health monitoring.<h3 dir="ltr">Automotive and Aerospace</h3>In transport sectors like automotive and aerospace, there are a number of innovative uses of printed electronics. For example, sensors can be embedded into vehicles and aircraft to monitor structural integrity and performance. These devices can alert users when maintenance is required. Printed electronics can also be used to make more lightweight devices, which add electronic functionality without adding bulky housings and weight to the vehicles.<h2 dir="ltr">Challenges Facing Printed Electronics</h2>While the advantages and potential of printed electronics are massive, the segment is still held back by some challenges, namely technical limitations, hurdles in market adoption, and questions of reliability over the long term.&nbsp;<ul><li dir="ltr">Technical Limitations:&nbsp;One of the main technical factors limiting printed electronics has to do with resolution. Most inkjet printing systems currently offer a spatial resolution above several micrometers, which limits miniaturization applications.[5]</li><li dir="ltr">Market Adoption:&nbsp;Conventional methods for producing PCBs are today so dominant that it is difficult for printed electronics to really get a foothold in the market. It is likely that printed electronics will not replace traditional PCBs in the near future but rather complement existing processes and unlock new capabilities.</li><li dir="ltr">Reliability and Durability: Since printed electronics are still an emerging technology, there are still questions about the durability of printed electronic materials over time. That said, studies have shown that printed conductive inks are both stable and reliable [6], even when using sustainable substrates like paperboard.[7]</li></ul>It’s worth mentioning that most of these challenges are related to the nascent stage of printed electronics and will be solved as the technology matures and as awareness and adoption increase. Notably, the continued growth of the IoT market will be particularly important for the proliferation of printed electronics, as more and more industrial and consumer products will benefit from thin and low-cost smart sensors. &nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA5ODAyMjAxNDQ2LXZvbHRlcmEgMi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">Voltera’s Role in Advancing Printed Electronics</h2>Voltera is among the innovators that has been helping to shape the future of printed electronics. The Canadian company has developed and brought to market two dispensing systems for printed electronics, the V-One and NOVA, both of which make the technology more accessible to a wide range of users.<h3 dir="ltr">V-One</h3><a href="https://hubs.ly/Q02gM0cd0" target="_blank">The V-One</a> is a sub-$10k system designed to accelerate the prototyping of PCBs. The desktop printer is based on an intuitive design and can be implemented in a range of environments, from classrooms, to electrical engineering labs, to R&amp;D departments. The V-One integrates multiple different functions into a single system, including circuit printing (using a printhead and conductive inks), drilling, solder paste application, and reflow soldering directly on the print bed.[8] The V-One enables users to print PCB prototypes in as little as an hour, which can then be tested, tweaked, and validated for production. In short, it offers greater flexibility and efficiency for the design and development of electronic circuit boards. Today, the V-One is used by product developers and educators in over 80 countries around the globe.<h3 dir="ltr">NOVA</h3><a href="https://hubs.ly/Q02gM0960" target="_blank">NOVA</a> is Voltera’s solution for printing electronic circuits. Based on a modular direct-ink-write dispensing system, NOVA can print a wide variety of conductive and dielectric inks onto substrates to create both rigid and flexible printed electronics. With a configurable print area of up to 220 x 300 mm and the ability to print traces down to 100 microns in width, NOVA accommodates a range of printed electronics, from small sensors with fine details to those with large surface areas. The machine is also equipped with a vacuum table and customizable fixturing, which facilitates the use of flexible or irregular substrates.[9] Overall, Voltera’s NOVA allows users to rapidly iterate and produce highly complex electronic circuits and experiment in the development of new printed electronic capabilities.&nbsp;<h2 dir="ltr">Conclusion</h2>Even as a relatively young technology, printed electronics are having a big impact, and there is no question that the low-cost production method for electronic circuits and sensors will continue to grow and evolve. Electronic printing technologies, such as Voltera’s V-One and NOVA systems, are vital to this growth. By making printed electronics more accessible and putting the technology into more people’s hands, Voltera is empowering researchers and innovators to explore and develop new applications for printed electronics. &nbsp; &nbsp;<h2 dir="ltr">References</h2>[1] TWI. “What is Physical Vapour Deposition?” 2023. Available from: <a href="https://www.twi-global.com/technical-knowledge/faqs/faq-what-is-physical-vapour-deposition-pvd" target="_blank">https://www.twi-global.com/technical-knowledge/faqs/faq-what-is-physical-vapour-deposition-pvd</a>&nbsp;[2] PCB Directory. “What is PCB Etching?” April 24, 2020. Available from: <a href="https://www.pcbdirectory.com/community/what-is-pcb-etching" target="_blank">https://www.pcbdirectory.com/community/what-is-pcb-etching</a>&nbsp;[3] Goosey M. Water use in the printed circuit board manufacturing process and approaches for reducing consumption. Circuit world. 2005 Jun 1;31(2):22-5. <a href="https://doi.org/10.1108/03056120510571815" target="_blank">https://doi.org/10.1108/03056120510571815</a>&nbsp;[4] Sanchez-Duenas L, Gomez E, Larrañaga M, Blanco M, Goitandia AM, Aranzabe E, Vilas-Vilela JL. A Review on Sustainable Inks for Printed Electronics: Materials for Conductive, Dielectric and Piezoelectric Sustainable Inks. Materials. 2023 May 24;16(11):3940. <a href="https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10253832/" target="_blank">https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10253832/</a>&nbsp;[5] Lemarchand J, Bridonneau N, Battaglini N, Carn F, Mattana G, Piro B, Zrig S, Noël V. Challenges, Prospects, and Emerging Applications of Inkjet‐Printed Electronics: A Chemist's Point of View. Angewandte Chemie International Edition. 2022 May 9;61(20):e202200166. <a href="https://doi.org/10.1002/anie.202200166" target="_blank">https://doi.org/10.1002/anie.202200166</a>&nbsp;[6] Chandrasekaran S, Jayakumar A, Velu R. A Comprehensive Review on Printed Electronics: A Technology Drift towards a Sustainable Future. Nanomaterials. 2022 Nov 29;12(23):4251. <a href="https://doi.org/10.3390/nano12234251" target="_blank">https://doi.org/10.3390/nano12234251</a>&nbsp;[7] Fu Z, Tanninen P, Keskinen J, Lev R, Leminen V, Mäntysalo M. Wear reliability and failure mechanism of inkjet-printed conductors on paperboard substrate. Flexible and Printed Electronics. 2023 Apr 24;8(2):025004. <a href="https://iopscience.iop.org/article/10.1088/2058-8585/accc9b/meta" target="_blank">https://iopscience.iop.org/article/10.1088/2058-8585/accc9b/meta</a>&nbsp;[8] Voltera. “V-One” 2023. Available from: <a href="https://www.voltera.io/v-one" target="_blank">https://www.voltera.io/v-one</a>[9] Voltera. “NOVA” 2023. Available from: <a href="https://www.voltera.io/nova" target="_blank">https://www.voltera.io/nova</a>&nbsp;


Printed electronics, characterized by their low cost and versatility through processes like inkjet or screen printing, are pivotal in advancing technologies such as wearable tech and the Internet of Things.

Unfolding the Future: The Evolution and Impact of Printed Electronics

Prototyping has always been an essential part of any product development, enabling engineers and inventors to test and validate their concepts and designs before moving into production. The same is true in the field of electronics, where new technologies and capabilities have been born out of tireless iteration and prototype cycles. Today, a new era of electronics prototyping is being ushered in thanks to the rise of rapid prototyping solutions like Voltera’s V-One platform. As we’ll see in more detail, this versatile piece of hardware is not only unlocking faster turnaround times for prototypes, but is also making electronics development&nbsp;<a href="https://www.wevolver.com/article/breaking-barriers-how-modern-tools-are-democratizing-electronics-design" target="_blank">far more accessible</a> than it has ever been.<h2 dir="ltr">A new era for prototyping electronics</h2>Most electrical engineers will be familiar with the once ubiquitous breadboard, a plastic perforated board used as a base to construct electronic circuit prototypes. While these offer an affordable way to test out some DIY electronic concepts, they have always been limited in terms of the voltages and currents they can handle and have not always been the most reliable. Breadboards are also limited to creating temporary electronics, since there is no soldering involved, which means they are good for proof-of-concept but not functional prototyping.Evaluation boards, for their part, are pre-built printed circuit boards (PCBs) that offer users different configuration options and can interface with other systems.[1] Evaluation boards have been a popular option for testing out a specific application on a functioning PCB. While both breadboards and evaluation boards are still used to develop circuits, they come with limitations. As we saw, breadboards have limited capacity for voltages and currents and, since they are not soldered, are not always reliable. Evaluation boards, for their part, are limited in terms of their function and complexity. And both, we should add, involve a significant amount of manual work.For more complex electronics prototyping, another option has been outsourcing prototyping to PCB manufacturers. In this case, a CAD design is sent to a PCB producer, where it is assembled using their industrial equipment and shipped to the customer. While the quality of these prototypes is typically high, so is the cost of the service (especially for small orders) and the turnaround time for parts, particularly when multiple design iterations are required. Ultimately, ordering electronic prototypes is not viable for small businesses or research groups with limited resources and strict development schedules.&nbsp;Fortunately, rapid prototyping technologies such as printing are offering an alternative to these more traditional routes. These technologies enable engineers and designers to create complex, functional electronic prototypes on demand and in house, which saves time and offers greater agility.[2] Moreover, benchtop systems like <a href="https://hubs.ly/Q02gM0cd0" target="_blank">Voltera’s V-One</a> are affordable to a wider range of users, making electronics development—and thus innovation—more accessible.&nbsp;<h2 dir="ltr">The V-One system</h2>Voltera’s V-One was specifically designed to address the challenges with traditional electronics prototyping and offer a straightforward and largely automated way to manufacture functional PCBs quickly and in house. The V-One is a benchtop printer that combines multiple functions into a single solution. Specifically, the machine can do everything from drilling through-holes, to printing traces, to depositing solder paste, and reflowing.&nbsp;From a user’s perspective, the V-One is intuitive and easy to use, whether you’re learning electronics or an experienced developer. Start by uploading a Gerber file to the printer, and the system will automatically generate a toolpath. Secure your substrate to the print area using the provided clamps. Next, attach the probe to create a topography of the board with 20 micron precision. If you require througholes of vias in your board, you can attach the drill head, then lay down the provided sacrificial layer to protect V-One’s heated bed from the drill. Once drilling is complete, you can remove the sacrificial layer and attach the ink dispenser printhead, which deposits material ink conductive ink and solder paste.&nbsp;When the traces are printed, users can cure the pattern directly on the print bed. It is also possible to print double-sided PCBs by simply flipping the cured board and repeating the process. When curing is complete, manually place rivets and then secure the PCB back onto the board along with the solder paste dispensing print head. Other electronic components can then be added to the board before using the reflow function to solder the PCB.[3]&nbsp;All in all, the V-One can produce PCB prototypes in under an hour and with minimal input from the user. This gives users the freedom to not only print PCBs quickly but also to test new designs, identify errors, and refine designs without adding significant time to the prototyping process. In the end this not only enhances efficiency but results in superior products. The V-One system is available for $5,199.98 USD.<h2 dir="ltr">The impact of Voltera’s benchtop solution</h2>The V-One is proving to be an indispensable prototyping tool for PCBs, and has been adopted by product developers and educators in over 80 countries, including Princeton University, Dyson, and NASA. The rapidity of the system is the biggest benefit, but there are also other ways that the V-One is improving the PCB prototyping process. For example, the V-One simplifies the workflow and eliminates steps like stenciling, which require the production and storage of design-specific stencils. Additionally, thanks to the system’s built-in heater, users no longer need a separate oven for soldering.&nbsp;Intellectual property protection is also more manageable with the V-One, as it enables developers to keep their designs and concepts fully in house without having to worry about the risks of outsourcing. In-house prototyping also helps to overcome supply chain challenges that can arise when developers are dependent on external parties for production. Overall, the printing platform allows users to rapidly iterate electronic designs, test them, adjust them when needed, and reprint for validation. What would have taken weeks or months can effectively be done within days or even hours.These benefits are experienced on the daily at Circuit Launch, a coworking community for electronics hardware entrepreneurs based out of Oakland, California. The facility houses a wide range of equipment that for individual entrepreneurs and startups would be too steep an investment, including a fully equipped woodshop, 3D printers, laser cutters, diagnostic tools, and the V-One. With access to the V-One and the other equipment, Circuit Launch members have developed a range of innovative technologies, including autonomous delivery robots, a bioprinter for tissue engineering, an AI-powered solar monitoring system and more. &nbsp;“Along with some of the other tools, [the V-One] brings the development time down so low,” says Dan O’Mara, COO of Circuit Launch. “Being able to take a designed circuit board and within about an hour, we can have it fully assembled. That’s incredible. The Voltera V-One has been pushing our entrepreneurs to create new things in a faster, more economical way than almost any of our other machines.”[4]<h2 dir="ltr">A new era for electronics prototyping</h2>Rapid prototyping solutions like the V-One are setting a new standard for electronics development based on efficiency and agility. With it, product developers and engineers can test new concepts and explore innovative designs from the comfort of their benchtop and without spending hours manually positioning wires and soldering. In the long-term, as adoption of the V-One and other electronics printing systems increases, we are likely to see the benefits of affordable benchtop solutions manifest as unprecedented innovation and new cutting-edge electronic capabilities and products.&nbsp;<h2 dir="ltr">References</h2>[1] Oborny, Nicholas. The Evolution of Electronic Prototyping [Internet]. Texas Instruments. April 15, 2015. Available from: <a href="https://e2e.ti.com/blogs_/b/industrial_strength/posts/the-evolution-of-electronic-prototyping" target="_blank">https://e2e.ti.com/blogs_/b/industrial_strength/posts/the-evolution-of-electronic-prototyping</a>&nbsp;[2] Vasquez S, Petrelli M, Angeli MC, Costa J, Avancini E, Cantarella G, Münzenrieder N, Lugli P, Petti L. Cost-effective, mask-less, and high-throughput prototyping of flexible hybrid electronic devices using dispense printing and conductive silver ink. In2021 5th IEEE Electron Devices Technology &amp; Manufacturing Conference (EDTM) 2021 Apr 8 (pp. 1-3). IEEE. Available from: <a href="https://doi.org/10.1109/EDTM50988.2021.9420858" target="_blank">https://doi.org/10.1109/EDTM50988.2021.9420858</a>&nbsp;[3] Voltera. Voltera V-One: PCB Printer Walkthrough [Video]. Youtube. August 10, 2018. Available from: <a href="https://www.youtube.com/watch?v=N6nEgN4THRE" target="_blank">https://www.youtube.com/watch?v=N6nEgN4THRE</a>&nbsp;[4] Voltera. Voltera at Circuit Launch: Building Hardware Faster [Video]. Youtube. January 8, 2019. Available from: <a href="https://www.youtube.com/watch?v=DqZHhqThCYU" target="_blank">https://www.youtube.com/watch?v=DqZHhqThCYU</a>

Voltera’s V-One benchtop printer is revolutionizing how electronics are developed with in-house, one-hour PCB prototyping.

Innovation at Your Benchtop: The Future of Rapid Prototyping

The adoption of healthcare monitoring devices that are both flexible and conform to the wearer have gained traction1. Spurred on by the need for remote care during the COVID-19 pandemic and technological advances in sensor accuracy, wearable health monitoring devices have become more ubiquitous in many areas of healthcare. In particular, there has been a rise in the development of wearable sensing and monitoring devices for telemedicine operations. Telemedicine has grown significantly in the last few years—and even more so during the COVID-19 pandemic when doctor-patient contact was limited—to remotely monitor patients in their own homes so hospitals could free up much-needed beds. While wearable technologies can be used in clinical environments to provide an analysis, much of their potential is in remote health monitoring.These wearable sensing devices typically make use of flexible materials, such as polymers, thin films, 2D materials and other nanomaterials. Health monitoring devices often consist of a flexible material that conforms to the wearer and is integrated with electronic components, including sensors, a power source—be it a battery, solar cell, or some other type of energy harvester like a nanogenerator—communication technologies if it transmits data to a central processing system, and any relevant circuitry.Building electronic components that are small and flexible enough to be used in wearable technologies is not that straightforward, and is why different nanomaterials—especially 2D materials—are often used to create the components because they fit the bill and can be easily integrated. But another approach is gathering interest: printing sensors—the most crucial aspects of a monitoring system—directly onto the wearable device.These printed sensors are sometimes made of 2D materials and other nanomaterials, but other materials can also be used as well. The ability to print sensors onto wearable health monitoring devices could pave a way to a much simpler and easier route to commercializing more wearable monitoring devices—especially if conventional, inexpensive, or easy-to-use printing technologies are used to print the sensor.<h2>Why Printed Sensors?</h2>While a range of advanced deposition and nanodeposition methods exist that can fabricate thin-film sensors on the substrate for wearable devices—often a soft polymer due to their flexibility and conformability—a number of biomedical sensors can be printed using screen printing techniques. Other techniques, such as inkjet and transfer printing, can be used as well, but screen printing is seen as the best option for printing sensors.Screen printing equipment is widely available, has a relatively low cost, and is easier to use than more advanced deposition methods, so it offers a much more scalable and commercially feasible route for using printed sensors in healthcare monitoring devices. Screen printing can also be used with many materials—from polymer solutions to conductive nanomaterial inks—so it is a versatile platform for printing a number of sensors.So, why print sensors instead of creating them through other manufacturing routes? Screen printing is a simple, fast, and efficient printing technique that can produce a large number of identical patterns in a single print. For large-scale operations and commercialization potential, screen printing can easily be adapted for mass production at a lower cost than other methods.From a performance perspective, screen printing provides high-resolution patterning and can print over large areas. The ability of screen printing to deposit material on demand in a given location also helps to reduce waste—especially on large scales—compared to traditional manufacturing methods because it is all done in a single step.There are, therefore, a number of manufacturing benefits with using printing methods. Beyond that, a greater design capability exists for health wearables because printing methods enable the production of sensors that are not only very thin but also provide the ability to print on the surface of the device. This approach is much simpler than trying to integrate devices into the material matrix of the wearable. You can also create a more customized sensor because you can print on demand, and the printing process can be changed to make a different sensor much easier than a typical manufacturing line.In terms of the materials compatible with screen printing, the scope is vast. Depending on the type of sensor being created, a whole host of materials can be used. On the one hand, a range of metals can be made into printable conductive inks to build the sensor. Common metals for wearable health sensors include gold, copper, platinum, nickel, aluminum, and silver. Beyond metals, a range of nanomaterial composites (graphene, carbon nanotubes composites), functional nanomaterial inks, and silver composites have all been used as the active sensing surface in printed health wearable sensors.The sensors also need a platform to be printed on. This often takes the form of a conductive polymer so that the sensor can better interact with the skin and the other components to provide higher sensitivity and reliability. PEDOT:PSS is the polymer platform that is most widely used for printed sensors, but other polymer materials include polyacetylene, polypyrrol, polyphenylene, poly (p-phenylene vinylene), and polythiophene polyaniline.<h2>The Printed Sensors of Interest in Healthcare Monitoring Applications</h2>Just as many materials can be used to create printed health sensors, many different types of printable sensors are used in health monitoring devices. Take, for example, strain-based sensors. Strain-based sensors measure a form of movement, and these wearable sensors are used in human-physiological signal monitoring and human-joint motion monitoring approaches.Another healthcare specialty measures different biomolecules and human signals. Non-strain-based sensors detect the biomolecule of interest directly or by directly measuring a physiological parameter that the patient exhibits. From a molecule-sensing perspective, a number of biomolecules in the blood can be detected, with glucose levels being a common one as well as the presence of sweat on a person’s skin. From a signal detection perspective, printed sensors can now detect respiration and heartbeat levels in a patient and provide remote electrocardiogram (ECG) monitoring.Another class of printed sensors for wearables is sensor arrays. In sensor arrays, multiple sensors work together to detect more complex issues or issues that require analysis from several stimuli angles. Sensor arrays are helpful in monitoring gait during walking, monitoring the sitting posture of wheelchair users, and monitoring the skin.Finally, there’s been advances in the development of printed temperature sensors for wearable health devices. Thermal sensing is a key area in disease detection because the body suffers thermal stresses when there is a disease present, and the rise in both skin and deep body temperature can be a primary indicator of a serious disease. Using printed temperature sensors, health wearables can detect a range of chronic diseases, such as cardiovascular, diabetic, and pulmonological diseases, as well as cancer.<h2>Conclusion</h2>Health monitoring wearables are gaining acceptance as an effective way to remotely measure many health factors of a patient. The most important aspect of these wearables is the sensing system that provides the analysis on the patient. For patients to be willing to wear the health monitoring device over an extended amount of time, the sensors and other components need to flex with the wearable component. While integrating flexible sensors is possible—for example, by using thin nanomaterials—printing sensors on the device’s surface is much easier, requires less material, and is much more scalable.A variety of printed health wearables are already in existence (commercially and academically. The printing methods discussed offer a route to achieve widespread distribution of health wearables. While many options are available, screen printing is the leading printing technology because it is highly versatile and can be used with many materials to create sensors that monitor different aspects of a person’s health—from heart rate to detecting a chance of a disease, to the different biomolecules in their blood, and many more in between.

The COVID-19 pandemic and advancements in sensor technology have led to the widespread adoption of wearable health monitoring devices, particularly for telemedicine, to facilitate remote patient monitoring.

Printable Sensors: A Key Technology for Health Wearables?

Circuit board components or SMDs etched on an electronic board

This guide provides an in-depth understanding of circuit board components, highlighting their basics, types, design process, and troubleshooting for various applications.

Understanding Circuit Board Components: A Comprehensive Guide

In a world that is increasingly dependent on electronic technology, electromagnetic compatibility (EMC) protection plays a vital role in a wide range of industries. Whether in automotive, aerospace, power generation or building services, EMC protection is essential to ensure the reliability, safety and performance of electronic systems.This requires a variety of techniques and materials. One of the most basic methods is the use of metal shielding, such as housings, cages and foils made of aluminium, copper or galvanised steel. These metal shields guide the radiation around sensitive components, preventing interference. Ferromagnetic materials such as iron and nickel can absorb and deflect magnetic fields to reduce radiation. EMC filters, consisting of components such as capacitors and coils, are used in power supply and signal processing circuits to suppress high frequency interference. Proper grounding is essential to dissipate unwanted electrical currents and minimise EMC problems. Twisted pair cables are commonly used in data transmission technology, where signal lines are twisted in pairs to reduce susceptibility to electromagnetic interference.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAzMjQ1MTEyOTQ4LTE3MDMyNDUxMTI5NDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Modern electronics, for example in medical technology, are making a significant contribution to groundbreaking progress. But this requires innovative, high-performance shielding solutions.EMC-compliant layouts also play an important role, allowing careful placement of traces, components and shielding on PCBs to minimise susceptibility to interference. Specialist engineers and designers take EMC requirements into account from the outset to avoid problems and identify them at an early stage. In some cases, software-based solutions can be used to detect and resolve problems. The choice of specific techniques and materials depends on the application, regulatory and technical requirements. Combinations of these methods and materials are often used to ensure effective EMC protection in electronic systems.<h3>Changing technology</h3>The automotive industry has changed dramatically in recent years, particularly with the advent of electric vehicles. These are equipped with a variety of electronic components that are critical to their function and safety. These include systems such as battery management, drive electronics and infotainment systems. EMC protection plays a key role in ensuring that these components function properly and are not compromised by electromagnetic interference. Interference from electromagnetic waves can not only lead to a loss of performance but can also endanger the safety of the vehicle occupants.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAzMjQ1MTY5MjkwLTE3MDMyNDUxNjkyODkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">The safety of electric cars depends largely on electronic assistance systems that monitor driving dynamics and intervene in dangerous situations. EMC problems could affect these systems and lead to serious accidents.The critical frequency range in electric cars extends from the low kilohertz to the gigahertz range, which causes strong electromagnetic emissions in the electronics between the electric motor and the battery. Voltages of 48 to 800 V with high currents are present in the high-voltage network of electric cars. Without effective shielding, this leads to significant interference in the vehicle's electronics, including safety-related control and infotainment systems. The charging of the traction batteries, both inductive and conductive, also generates disturbing stray radiation, including low-frequency interference signals in electronic modules controlling acceleration and braking. The importance of electromagnetic shielding in electric vehicles is emphasised by legal requirements ranging from EU directives to ICNIRP and CISPR to protect vehicle occupants and technical systems.<h3>High-performance, flexible round and flat wire mesh solutions</h3>In addition to traditional round wire meshes, innovative flat wire meshes offer electromagnetic and mechanical advantages. This solution, developed and customised by Haver &amp; Boecker, allows a higher surface density for a comparable mesh size compared to conventional shielding, resulting in significantly higher performance. Measurements show excellent shielding attenuation <s>&nbsp;</s>in the MHz range, relevant for onboard electrical systems in electric cars, aerospace applications and other areas such as building and medical technology.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAzMjQ1MjEzOTY5LTE3MDMyNDUyMTM5NjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Depending on the installation environment, the perforated fabric elements are fitted with either plastic and metal frames or fasteners.The meshes also offer excellent mechanical stability, low weight and optimum adaptability to installation conditions. State-of-the-art manufacturing ensures precision and repeatability, and the properties of the moulded parts can be precisely defined by parameters such as wire diameter and mesh width. Flat wire mesh is flexible and dimensionally stable, making it ideal for enclosing or covering components. Large-area shielding, including battery encapsulation, can also be achieved. It also provides a high level of protection against condensation, overpressure and explosion hazards in the event of an accident. For various applications, fabric elements are combined with plastic or metal housings and fasteners. In the field of electromagnetic compatibility (EMC), the moulded parts are equipped with stamped or stamped-bent parts such as metal surrounds or EMC springs. An innovative welding process is used to ensure that induced eddy currents are safely dissipated via the weld seams.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAzMjQ1MjQyNDU0LTE3MDMyNDUyNDI0NTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Round and flat wire cloths can be optimally adapted to the respective installation situation, are robust and powerful and, thanks to their reproducibility, also ensure a high level of cost-effectiveness in series production.<h3 id="isPasted">EMC protection in other applications</h3>Other areas where newly developed round and flat wire meshes are being used include medical imaging systems (MRI, CT), data centres and the aerospace industry, with its extremely high demands on the safety and reliability of systems. Modern aircraft, for example, are equipped with sophisticated electronic navigation and communication systems. An EMC failure could affect the accuracy of navigation or disrupt communication with the flight control centre, which could also lead to serious safety problems. Another area is power generation. This includes power plants and energy infrastructures that rely on a continuous supply of electricity. Building technology is also heavily influenced by electronic systems that ensure comfort, safety and energy efficiency. Intelligent building automation solutions control lighting, heating, air conditioning and security systems.EMC protection is essential in the connected and electronic world of industry. From automotive and aerospace to power generation and building services, it is a critical factor in the safety, reliability and performance of electronic systems. Companies and organisations in these industries should consider EMC protection a priority to avoid catastrophic failures and safety risks. It is foreseeable that more applications will be added in the future.<h3>Tailored to the process &nbsp; &nbsp; &nbsp;&nbsp;</h3>The choice of material for woven wire meshes depends on the customer's requirements and the application. Haver &amp; Boecker offers a wide range of high-tech wire meshes that provide high-quality solutions for EMC-critical assemblies in electric mobility. Haver &amp; Boecker's experts work together with the customer to develop custom moulded parts that meet specific manufacturing requirements. Ready to learn more? Gain in-depth insight with the exclusive EMC white paper.<a href="https://drahtweber.haverboecker.com/a.php?sid=5iehw.tkic9f,f=7?lso=wewolver-emv-beitrag&utm_campaign=emv&utm_source=wewolver&utm_medium=beitrag&utm_content=_122023_EN" target="_blank" rel="noopener noreferrer">Download now</a>

In a world that is increasingly dependent on electronic technology, EMC protection plays a vital role in a wide range of industries.  Whether in automotive, aerospace or power generation, EMC protection is essential for the reliability, safety and performance of electronic systems.

Electromagnetic Compatability protection in industry: The indispensable pillar for safe and reliable systems

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flexible electronics

flexible electronics

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