Steve Paschky | Saralon GmbH: Can printed inks replace traditional wiring in stretchable, 3D-formed, and self-heating structural electronics?
00:07:54 - 00:10:21
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Can printed inks replace traditional wiring in stretchable, 3D-formed, and self-heating structural electronics?
Printed electronics are rapidly moving beyond rigid substrates into complex three-dimensional forms and flexible materials. For smart textiles, medical wearables, and automotive interiors, a complete stretchable ink set—incorporating dielectric, carbon, and silver materials—is now available. These formulations can be screen-printed directly onto thermoplastic polyurethane (TPU) or textiles, allowing circuits to flex and deform without losing electrical continuity.
In tandem with stretchability, thermoformable inks are enabling the integration of human-machine interfaces (HMI) directly into three-dimensional plastic parts. This in-mold electronics (IME) approach simplifies assembly by printing conductive traces directly onto a flat sheet before it is thermally shaped into a 3D component. This technique is gaining rapid traction in both consumer electronics and automotive cockpits to reduce weight and mechanical complexity.
Furthermore, the shift to electric vehicles (EVs) has created a unique demand for printed surface heaters. Because EVs lack waste heat from an internal combustion engine, energy-efficient cabin heating must be generated directly on interior surfaces. Printed heaters provide a lightweight, highly customizable alternative to traditional wire-wound systems, distributing heat evenly across structural surfaces.
In this short video, you can learn:
* How stretchable ink sets printed on TPU enable flexible electronics for wearables and automotive interiors.
* The role of thermoformable conductive inks in fabricating complex, three-dimensional HMI components.
* Why printed surface heaters are becoming critical for thermal management in modern electric vehicle cabins.
📋 **Clip Abstract** This clip highlights Saralon's advanced portfolio of functional inks designed for stretchable textiles, 3D thermoformed interfaces, and surface heating. Steve Paschky details how these customizable materials are solving complex design challenges in automotive, healthcare, and consumer electronics.
#InMoldElectronics, #ThermoformableInks, #PrintedSurfaceHeaters, #StretchableConductiveInks, #StructuralElectronics, #SmartTextiles
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00:01:18 - 00:02:28
Why is the automotive industry abandoning flat control panels for 3D stretchable electronics?
How can printed electronics manufacturers capture their share of a projected multi-billion-dollar market as control interfaces transition from rigid mechanical switches to seamless, three-dimensional surfaces?
The market for stretchable electronics is undergoing a massive commercial expansion, with its global volume projected to surge from approximately half a billion US dollars today to an estimated 3.3 billion US dollars by 2032. This rapid trajectory represents a compound annual growth rate of roughly 23 percent, signaling a profound shift in how industries approach product design and electronic integration.
This commercial momentum is primarily propelled by the automotive sector and manufacturers of three-dimensional Human-Machine Interface (HMI) applications. Modern consumer expectations have moved away from traditional, tactile button-based control panels in favor of seamless, three-dimensional, and flexible control interfaces that can be integrated directly into complex, curved structural elements.
To meet these rigorous design and mechanical requirements, advanced material formulation is shifting toward fully compatible functional ink sets rather than isolated materials. Developing cohesive ink systems, such as specialized stretchable heater inks, allows manufacturers to deliver complete, robust material solutions that maintain electrical performance under mechanical deformation.
In this short video, you can learn:
* The projected market volume and compound annual growth rate for stretchable electronics leading up to 2032.
* The primary industries and application areas driving the transition toward three-dimensional, flexible control panels.
* The importance of developing fully compatible functional ink sets, including stretchable heater inks, to meet new manufacturing demands.
📋 **Clip Abstract** The speaker discusses the rapid market growth of stretchable electronics, which is projected to reach 3.3 billion US dollars by 2032 due to demand from the automotive and 3D HMI sectors. He explains that his company is addressing these new design requirements by introducing compatible functional ink sets, starting with stretchable heater inks.
🎤 Speaker: Steve Paschky
🏢 Company: Saralon
📅 Event: Additive, Sustainable or 3D Electronics Innovations Day 2025
📍 Location: TechBlick Online Platform
🌐 Learn more at the next TechBlick event: https://www.techblick.com
#ThermoformableConductiveInks, #CoFormulatedInkSets, #AutomotiveHMI, #3DStructuralElectronics, #InMoldElectronics, #PrintedElectronics
00:11:16 - 00:12:00
Can copper inks successfully replace expensive silver in next-generation perovskite solar cells?
Can copper inks successfully replace expensive silver in next-generation perovskite solar cells?
The printed electronics industry is facing a significant supply bottleneck due to the decreasing availability and soaring cost of silver. To maintain economic viability, material scientists are aggressively researching and developing alternative base-metal inks, specifically targeting copper-based formulations.
A key focus area for this transition is the field of perovskite solar cells, where stretchable and transparent electrodes are critical for flexible photovoltaics. European-funded initiatives are currently validating copper ink performance to replace traditional silver electrodes.
Transitioning to copper inks requires solving complex challenges related to oxidation and curing compatibility with sensitive perovskite layers. Overcoming these formulation hurdles will enable highly scalable, low-cost solar cell manufacturing independent of silver market volatility.
In this short video, you can learn:
* The economic drivers pushing the printed electronics industry to replace silver with copper.
* How copper inks are being integrated into European-funded perovskite solar cell research.
* The material challenges involved in formulating stretchable alternative metal electrodes.
📋 Clip Abstract: This clip discusses the market transition from silver to copper inks in response to supply shortages and rising raw material costs. The speaker highlights an active European project focused on integrating copper electrodes into perovskite solar cells.
#CopperInks, #PerovskiteSolarCells, #StretchableElectrodes, #FlexiblePhotovoltaics, #PrintedElectronics, #AdditiveElectronics
00:04:17 - 00:05:41
How do you engineer a heating system that can stretch over 300% without electrical failure?
How do you engineer a heating system that can stretch over 300% without electrical failure?
Developing robust stretchable surface heaters requires a complete, chemically compatible system rather than a single conductive ink. This integrated system relies on three distinct layers: high-conductivity silver, resistive carbon for heat generation, and a protective transparent dielectric barrier.
The formulation chemistry achieves remarkable mechanical performance, with the stretchable silver and transparent dielectric layers tolerating elongation levels exceeding 300 percent. The silver layer maintains a low sheet resistance of approximately 30 milliohms per square, while the carbon heating element stretches up to 100 percent.
Protecting printed functional layers from environmental factors like humidity is critical for long-term reliability in automotive interiors, healthcare devices, and sportswear. A stretchable, transparent dielectric coating is essential to seal and preserve the integrity of the underlying circuit during repeated mechanical strain.
In this short video, you can learn:
* The three essential ink layers required to print a fully functional stretchable surface heater.
* The elongation thresholds and sheet resistance values of advanced silver and carbon inks.
* Why a stretchable dielectric layer is crucial to protect printed electronics from ambient conditions.
📋 Clip Abstract: The speaker details the composition of an entire stretchable heater ink set, including a 300 percent stretchable silver conductor, a 100 percent stretchable carbon heating element, and a transparent dielectric. This compatible material system is engineered to withstand environmental moisture and high mechanical strain in demanding automotive and wearable applications.
#StretchableSurfaceHeaters, #StretchableConductiveInks, #StretchableDielectrics, #PrintedElectronics, #WearableElectronics, #AutomotiveInteriors