Andrew Strudwick | Graphene Engineering and Innovation Centre - University of Manchester: What does it take to move printed graphene devices from the lab bench to pilot-scale production?
00:08:22 - 00:09:51
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Summary of the clip:
What does it take to move printed graphene devices from the lab bench to pilot-scale production?
Scaling up from lab-scale prototyping to industrial production is a critical challenge in printed electronics, and the GEIC bridges this gap with its pilot-scale roll-to-roll (R2R) capabilities. The facility features a Tima base coater equipped with multiple print heads, including gravure, slot-die, and flexographic systems. This setup allows for the translation of lessons learned from screen printing and other benchtop methods to a continuous, higher-throughput process that mimics industrial manufacturing.
This R2R system is not for mass production but serves as an essential pilot line to test and de-risk the upscaling of methods and processes. It enables the optimization of ink formulations, substrate handling, and printing parameters in a dynamic R2R environment. By proving process viability at this intermediate scale, the GEIC helps partners build the confidence and data needed to engage with full-scale contract manufacturers.
Underpinning all printing and scaling activities is a deep-seated expertise in material characterization. The ability to precisely measure the properties of the novel materials and printed layers is non-negotiable for process control and quality assurance. The GEIC leverages an extensive suite of in-house metrology tools, with access to the full range of advanced characterization equipment across the University of Manchester campus, ensuring that every step of the scaling process is backed by robust data.
In this short video, you can learn:
* The role of pilot-scale roll-to-roll (R2R) systems in upscaling printed electronics.
* How lessons from screen printing can inform R2R process development.
* The critical importance of advanced material characterization for process control and quality assurance.
📋 **Clip Abstract** This clip explores the pathway from lab-scale prototyping to pilot-scale manufacturing using roll-to-roll systems. It emphasizes that comprehensive material characterization is the essential foundation for successfully upscaling printed electronics.
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#RollToRollPrinting, #PilotScaleProduction, #MaterialCharacterization, #PrintedGraphene, #PrintedElectronics, #FlexibleElectronics
This is a highlight of the presentation:
Graphene and 2D Material Inks: Conductive, Optical and Beyond
More Highlights from the same talk.
00:08:56 - 00:10:02
Can we de-risk the transition of novel 2D formulations to high-throughput roll-to-roll manufacturing without risking production line downtime?
Can we de-risk the transition of novel 2D formulations to high-throughput roll-to-roll manufacturing without risking production line downtime?
Transitioning a novel 2D material ink formulation from laboratory vial to high-volume production remains one of the largest bottlenecks in printed electronics. Industrial roll-to-roll coating lines are reluctant to allocate expensive machine time to unproven formulations, leaving a massive scaling gap for advanced material developers.
The Graphene Engineering Innovation Centre addresses this by utilizing a pilot-scale Ultima Baseline coater configured for flexographic, gravure, slot-die, and rotary screen printing. This intermediate platform allows researchers to evaluate fluid dynamics, drying profiles, and substrate interactions under realistic web tensions and shear rates.
By generating a robust parameter dataset at a pilot scale, innovators can present production facilities with proven run conditions. This systematic de-risking of ink viscosity, coating speed, and drying temperature reduces industrial adoption barriers and accelerates the commercialization of flexible electronics.
In this short video, you can learn:
* How pilot-scale slot-die and gravure printing bridge the gap between lab-scale ink formulation and volume manufacturing.
* The strategic importance of de-risking machine run-time on industrial roll-to-roll web presses.
* How to systematically validate novel substrates and 2D material binders under realistic shear environments.
📋 **Clip Abstract** This clip details how the GEIC leverages pilot-scale roll-to-roll coating technology to test and validate advanced 2D material formulations. By optimizing deposition techniques like slot-die and gravure on a pilot scale, they significantly de-risk the transition to commercial production lines.
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#RollToRollCoating, #SlotDieCoating, #2DMaterialInks, #PilotScaleValidation, #PrintedElectronics, #FlexibleElectronics
00:18:00 - 00:18:58
Why does graphene outperform other carbon-based additives in flexible printed electronics and composite materials?
Why does graphene outperform other carbon-based additives in flexible printed electronics and composite materials?
The choice of conductive carbon additives in printed inks determines how well a flexible electronic device will perform under cyclic mechanical stress. Graphene offers unique morphological advantages over zero-dimensional carbon blacks, maintaining superior electrical percolation pathways even under extreme bending.
While formulating custom inks from scratch is often unnecessary due to the availability of mature commercial formulations, selecting the right material morphology is critical. Graphene's two-dimensional structure allows flakes to slide and maintain contact during substrate flexing, preserving device conductivity where standard carbon structures would fracture.
Furthermore, combining different carbon nanomaterials yields powerful synergistic effects. Hybridizing two-dimensional graphene with one-dimensional carbon nanotubes creates a hierarchical network that significantly improves electrical conductivity and mechanical reinforcement in both printed electronics and advanced composite matrices.
In this short video, you can learn:
* The mechanical and electrical advantages of 2D graphene flakes compared to other carbon allotropes in flexible form factors.
* How to select commercial ink formulations tailored specifically to dynamic stress and bending requirements.
* The engineering principles behind hybridizing graphene with carbon nanotubes to optimize electrical percolation in composite systems.
📋 **Clip Abstract** This clip explains why graphene is the preferred additive for maintaining electrical conductivity in flexible and dynamic electronic applications. It also introduces the concept of hybrid carbon systems, demonstrating how pairing graphene with carbon nanotubes yields superior electrical and mechanical performance.
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#GrapheneConductiveInks, #ElectricalPercolation, #HierarchicalCarbonNetworks, #CyclicMechanicalStress, #PrintedElectronics, #FlexibleElectronics
00:13:47 - 00:14:28
How do you transition delicate benchtop 2D-material characterization into inline quality control for high-speed manufacturing?
How do you transition delicate benchtop 2D-material characterization into inline quality control for high-speed manufacturing?
To successfully transition printed 2D materials from low-volume prototyping to gigafactory scales, real-time metrology is indispensable. Traditional characterization methods are destructive, slow, or require contact, making them incompatible with rapid, continuous roll-to-roll printing speeds.
In collaboration with the National Physical Laboratory, researchers integrated a non-contact magnetic resonance cavity directly onto a roll-to-roll web coater. This integration enables the non-destructive measurement of electrical conductivity of printed graphene tracks as they pass through the system in real time.
This transition from stationary benchtop evaluation to continuous inline monitoring is a vital step forward for quality control. It allows immediate adjustment of deposition parameters, ultimately driving down defect rates and ensuring sheet-resistance uniformity across large-scale flexible substrates.
In this short video, you can learn:
* The integration of non-contact magnetic resonance cavities into continuous web coating equipment.
* How to perform inline, real-time electrical conductivity monitoring on moving graphene tracks.
* The role of standardizing body collaborations in shifting characterization from R&D into production-grade quality control.
📋 **Clip Abstract** This clip highlights a collaborative project between the GEIC and the National Physical Laboratory to implement inline quality control for printed graphene. By adapting a non-contact magnetic resonance sensor to a pilot coater, they demonstrate real-time electrical conductivity measurements on active production webs.
🔗 Link in comments 👇
#MagneticResonanceCavity, #InlineMetrology, #PrintedGraphene, #RollToRollProcessing, #PrintedElectronics, #FlexibleElectronics