<h2>Introduction to in-house PCBA</h2><p>When turning electronics designs into prototypes, outsourcing PCB assembly may seem convenient. But for agile hardware teams, it is often a hidden liability. Between iteration slowdowns, lost opportunities, and IP risks, the costs of sending prototypes out of house quickly add up.</p><p>The smarter path? Bringing PCB assembly (PCBA) in-house with tools like a <a href="https://www.voltera.io/blog/pcba-guide-pick-place-options?id=68cb1fe64e49257855c7e259#In-house_automated_pick_and_place">pick and place (PnP) machine</a>. It compresses time to market (TTM), safeguards strategic design assets, and ensures you're ready to act fast when it matters most.</p><p>Let’s explore why in-house PCBA makes sense for hardware teams.</p><h2>Faster iteration means faster product delivery</h2><h3>It is non-negotiable.</h3><p>Hardware teams face more friction than their software counterparts when it comes to prototype iteration, even when applying agile project management principles. <a href="https://journals.plos.org/sustainabilitytransformation/article?id=10.1371/journal.pstr.0000101">Research </a>shows prototyping to be the longest phase in hardware product development, averaging nearly 19 weeks per iteration.</p><p>When it comes to PCB assembly, outsourcing often adds hidden friction, such as:&nbsp;</p><ul><li>Long lead times</li><li>Minimum order requirements</li><li>Coordination overhead</li></ul><p>Through expert interviews across the electronics space, Voltera’s market research team found that overseas assembly often takes far longer than anticipated. One hardware team based in North America reported that preparing parts, shipping them overseas, and waiting for completed boards to return routinely stretched into a six- to eight-week cycle — a lead time they described as both “<em>inefficient and unacceptable</em>” for rapid prototyping.</p><p>Delays in PCB prototyping often cause downstream ripple effects to project schedules and eventually hinder product delivery. A widely cited <a href="https://hbr.org/1991/01/the-return-map-tracking-product-teams">McKinsey study</a> found that a product arriving six months late can slash after-tax profit by roughly 33%, whereas a 50% budget overrun only cuts profit by 4%.&nbsp;</p><blockquote><em> A product arriving 6 months late cuts profit by 33%</em></blockquote><p>In other words, speed is the advantage, especially when bringing a novel product to market first matters most.&nbsp;</p><p>With in-house pick and place systems designed for prototyping, engineers can cycle through build-test-fix loops in hours, not days or weeks. This is essential for rapidly building and validating minimal viable products (MVPs) and compressing time to market.</p><h2>Every delayed prototype is a stolen opportunity</h2><h3>Outsourcing delays do more than frustrate engineers — they cripple business momentum.</h3><p>When PCB prototypes arrive behind schedule, or are flawed, teams may miss internal deadlines, investor presentations, customer demos, or pilot deployments. That pause can mean cancelled contracts, diminished credibility, and financial loss. <a href="https://www.spkaa.com/blog/navigating-the-high-costs-of-product-launch-delays">Research</a> shows that for a $50M product with a 30% margin, even a single month’s delay equates to $1.4M in lost opportunity.&nbsp;</p><p>When speaking to business leaders, we learned about the uncertainties of outsourcing PCB assembly and how it directly impacts real-world business opportunities.</p><blockquote><em>“The problem is not the cost, but the risk. When you receive your prototype but it needs rework, you add another two weeks. Since you’re on a delivery deadline, that is really not good.“</em><br>— A CEO of an electronics manufacturing company in Canada </blockquote><p>The true cost of waiting on outsourced boards isn’t just your engineers’ hourly wages, it is the opportunity cost to your entire business. By keeping assembly in-house, you maintain control of your workflow and safeguard critical business opportunities instead of leaving them to chance.&nbsp;</p><h2>Protecting your intellectual property</h2><h3>Secrets stay secret when they are in your own hands.</h3><p>When you outsource prototype assembly, you expose your sensitive designs: files, bills of material, layout data, and more leave the safety of your firewall, often traveling farther than intended, if vendors subcontract the work. Many development teams, particularly in advanced manufacturing and regulated sectors, fear design leakage, counterfeits, or unintended reverse engineering.&nbsp;</p><blockquote><em>Manufacturers face 2× higher IP theft risk</em></blockquote><p>According to the <a href="https://www.kroll.com/en/reports/global-fraud-and-risk-report-2019/industry-overview/manufacturing"><em>Global Fraud and Risk Report</em></a>, manufacturing is significantly more likely than other industries to have experienced IP theft (43% vs. 24% for all industries). This is amplified by the fact that more than 75% of businesses now treat third-party risk management as a strategic imperative, according to <a href="https://assets.kpmg.com/content/dam/kpmgsites/uk/pdf/2021/04/outsourcing-and-third-party-risk.pdf">KPMG</a>.</p><p>Retaining in-house PCB assembly capabilities keeps your IP under close guard, avoids third-party vulnerabilities, and ensures you stay in control of your most valuable asset: your innovations.</p><h2>Supply chain challenges</h2><h3>Both predictable and unforeseen challenges squeeze small teams.&nbsp;</h3><p>Time to batten down the hatches.</p><p>Electronics manufacturing services capacity is tightening, especially in North America. Shipments rose <a href="https://www.electronics.org/news-release/north-american-ems-industry-17-percent-february">1.7%</a> year-over-year in February 2025, and <a href="https://emails.ipc.org/links/IPC-0425Current-Sentiment-Global-EMSChain.pdf">57%</a> of manufacturers expect continued demand growth over the next 6-12 months. This upward movement in EMS demand may result in longer queues, slower turnaround for low-volume orders, and higher costs — exactly the opposite of what agile teams need.&nbsp;</p><p>Foreign imports to the U.S. stumble. As of August 29, 2025, the United States removed the duty exemption for imports valued under $800 USD (known as <a href="https://www.nbcnews.com/business/economy/companies-making-money-tariffs-de-minimis-ends-rcna230320">de minimis</a> items) subjecting them to significant tariffs. This change directly affects PCBs fabricated offshore entering the U.S., further driving up the cost of electronics development.</p><p>To weather the storm, more hardware teams are investing in in-house PCB fabrication and assembly setups — not to replace EMS entirely, but to keep rapid iteration channels internal, retaining speed and autonomy.</p><h2>Conclusion: The three pillars of in-house PCB assembly</h2><p>In-house PCB assembly delivers value across three interconnected strategic fronts:&nbsp;</p><ul><li>Development speed — In-house assembly cuts outsourcing delays, shortens time-to-market, and enables quick pivots when requirements change. In hardware, speed isn’t just efficiency; it’s survival.</li><li>Business opportunity — Faster prototyping safeguards critical milestones like demos, pilots, and compliance tests. What once took weeks can now happen overnight, turning agility into business wins.</li><li>IP security — Keeping assembly internal protects designs, limits third-party risks, and ensures sensitive innovations stay secure, essential for competitive and regulated hardware teams.</li></ul><p>Together, these three pillars — speed, opportunity, and security — make in-house PCB assembly not just a technical upgrade but a strategic leap forward. By complementing traditional EMS partners with in-house capabilities such as a pick and place machine, hardware teams future-proof their workflows and give themselves the freedom to move fast, stay secure, and seize every opportunity the market presents.</p><p>Interested in learning more about PCB prototyping and assembly? Check out these resources:</p><ul><li>Application: <a href="https://www.voltera.io/use-cases/applications">PCB Prototyping</a></li><li>Blogs:&nbsp; <br><ul><li><a href="https://www.voltera.io/blog/pcba-guide-pick-place-options">What is PCBA? A Guide to Pick and Place Options</a></li><li><a href="https://www.voltera.io/blog/prototype-pcbs-in-house">How to prototype PCBs in-house?</a></li><li><a href="https://www.voltera.io/blog/3d-printing-pcb-printing-difference">3D Printing vs. PCB Printing — What’s the Difference?</a></li></ul></li></ul><p>Discover how Voltera is transforming PCB assembly with <a href="https://info.voltera.io/alta-pick-and-place?utm_campaign=31752028-Alta%20Launch&utm_source=Website&utm_medium=blog&utm_term=in-house-pcb-assembly-next-leap-agile-hardware-teams&utm_content=Alta">Alta</a>, our new desktop pick and place machine designed to streamline in-house prototyping.</p>

Why In-House PCB Assembly is the Next Leap for Agile Hardware Teams

Outsourcing PCB assembly costs more than it appears. Discover its hidden liabilities and why hardware teams are bringing builds back in-house.

<p><a href="https://www.voltera.io/blog/flexible-hybrid-electronics">Flexible hybrid electronics</a> (FHE) continue to reshape how engineers design and manufacture next-generation devices, from flexible sensors and smart labels to wearable electronics and hybrid systems. As the FHE industry continues to evolve, the role of reliable, scalable <a href="https://www.voltera.io/blog/what-are-functional-inks">functional materials</a> becomes more critical than ever.</p><p>We recently had a conversation with <a href="https://fr.linkedin.com/in/bianca-verneuil-a7928741" target="_blank">Bianca Verneuil</a>, Head of Communications &amp; Marketing at VFP Ink Technologies, to discuss VFP’s mission in additive electronics, the capabilities of VFP’s <a href="https://www.vfp-ink-technologies.com/product/silver-electron-low-energy-curing" target="_blank">Silver Electron ink</a>, and how developers can move seamlessly from prototyping to mass manufacturing.</p><h2>VFP Ink Technologies and its mission</h2><p><strong>Q: Can you briefly introduce VFP and its mission in the field of additive electronics?</strong></p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6967bfcdd86aebe01b651785_vfp-functional-inks-prototyping-led-display.webp" loading="lazy" alt="An LED display of VFP’s logo with red LED strips on top of conductive traces printed on three pieces of PET sheets" width="auto" height="auto"></div><figcaption>VFP Silver Electron used for display</figcaption></figure><p>A: VFP Ink Technologies is a French manufacturer specializing in high-performance functional inks for printed and additive electronics. For more than 10 years, our mission has been to provide the industry with reliable, scalable, and application-driven materials that enable new generations of flexible and hybrid electronic devices.</p><p>Our expertise covers conductive silver and carbon inks, dielectric varnishes, functional varnishes, and more recently, advanced specialty materials such as piezoelectric inks. We work closely with OEMs, research institutions, and production partners to bridge the gap between laboratory innovation and industrial-grade manufacturing.</p><p>At the core of our philosophy is a commitment to process simplification, environmental responsibility, and strong application support, allowing designers and engineers to move from concept to prototype and from prototype to mass manufacturing with confidence.</p><h2>Benefits of VFP’s Silver Electron ink</h2><p><strong>Q: What makes VFP’s Silver Electron ink stand out and what are some benefits of using it for flexible electronics prototyping?</strong></p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6967bfaecfdc7441b9a70d42_vfp-functional-inks-prototyping-silver-electron.webp" loading="lazy" alt="a single 2 mL cartridge of VFP’s Silver Electron ink (SE) for prototyping flexible electronics" width="auto" height="auto"></div><figcaption>VFP Silver Electron ink</figcaption></figure><p>A: <a href="https://store.voltera.io/products/vfp-silver-electron-ink-2ml-cartridge-copy">VFP’s Silver Electron (SE) ink</a> stands out thanks to its combination of high electrical stability, mechanical flexibility, and broad substrate compatibility. After curing, SE maintains very stable conductive properties over time, offering a resistivity of ≤ 15 mΩ/sq/mil, even after mechanical stress such as a net fold. It also provides excellent adhesion (ISO 2409 Class 0), ensuring reliable performance across demanding applications.</p><p>SE ink is designed for versatility. It can be printed on a wide range of substrates for diverse printed electronics use cases. Compatible substrates include:</p><ul><li>Paper and cardboard</li><li>PVC, PET, and polycarbonate</li><li>Treated polyester</li><li>Glass and polyimide</li></ul><p>This <a href="https://www.voltera.io/blog/conductive-inks">conductive ink</a> is optimized for automatic, semi-automatic, and manual screen-printing processes, with consistent deposition thickness (8-9 µm at 90 threads/cm) and no dilution required before use. Thanks to its flexibility, stability, and ease of processing, SE offers a dependable and efficient silver conductor suitable for both industrial and specialized applications, while maintaining strong mechanical and chemical durability.</p><p>Key prototyping advantages of SE include:</p><ul><li>Low-temperature curing, allowing quick proof-of-concept production without damaging flexible substrates</li><li>Excellent flexibility and mechanical stability, enabling the rapid creation of foldable, bendable, or wearable circuits</li><li>Stable adhesion and chemical resistance, essential for multi-step experiments or complex assemblies</li><li>Clean printability, ensuring consistent geometries even with small prototypes.</li><li>Non-CMR (carcinogenic, mutagenic, reprotoxic), aligning with sustainability goals for development programs</li></ul><p>These characteristics make the ink suitable for prototyping <a href="https://www.voltera.io/use-cases/applications/flex-sensors">sensors</a>, <a href="https://www.voltera.io/use-cases/white-papers/connecting-flexible-stretchable-substrates-printed-circuit-boards">interconnects</a>, <a href="https://www.voltera.io/use-cases/applications/flexible-pcbs">flexible circuits</a>, <a href="https://www.voltera.io/use-cases/applications/electroluminescent-displays">smart labels</a>, and <a href="https://www.voltera.io/use-cases/applications/printed-batteries">low-power embedded modules</a>.</p><h2>Scaling from prototyping to production with VFP’s Silver Electron ink</h2><p><strong>Q:</strong> <strong>How does VFP address compatibility between the Silver Electron ink and direct ink writing and screen printing?</strong></p><p>A: The ink was designed with cross-process compatibility in mind from the start. Its rheology supports:</p><ul><li><a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">Direct ink writing (DIW)</a> for rapid prototyping, small-batch production, and custom geometries</li><li><a href="https://www.voltera.io/blog/introduction-screen-printing">Screen printing</a> for thicker layers, uniform deposition, and scalable industrial production</li></ul><p>Our R&amp;D teams carefully optimized solids content, viscosity, and drying behavior to ensure clean line definition and stable conductivity across both processes.&nbsp;</p><ul><li>For DIW, the ink maintains consistent flow and good extrudability.&nbsp;</li><li>For screen printing, it performs reliably with polyester or stainless-steel meshes between 79 and 120 threads/cm.</li></ul><p>This dual compatibility enables designers to prototype quickly with DIW, then transition the exact same ink to industrial screen printing without reformulation.</p><p><strong>Q: How well does the ink scale from prototyping to mass manufacturing (screen printing)?</strong></p><p>A: The ink scales extremely well because it was originally formulated for industrial screen printing, then optimized for DIW. Its stable drying, low-temperature cure, reproducible viscosity, and adhesion profile all make it compatible with automated screen-printing lines. Manufacturers can move from bench-top DIW prototypes, such as those made using <a href="http://www.voltera.io/products/nova">NOVA</a>, to high-throughput production, using the same ink and achieving consistent electrical and mechanical performance. This fluid transition reduces development time and eliminates reformulation risk.</p><h2>Additional resources</h2><p>If you’d like to learn more about VFP Ink Technologies’ printed electronics portfolio, request samples, or get technical support, you can reach out directly:</p><ul><li>📩 Email: <a href="mailto:lgiacomini@vfp-ink.com">lgiacomini@vfp-ink.com</a>, Product Manager for Printed Electronics Inks, VFP Ink Technologies</li><li>🌐 Website: <a href="http://www.vfp-ink-technologies.com">www.vfp-ink-technologies.com</a>&nbsp;</li><li>💬 Technical support: Available through VFP’s product managers and sales teams across Europe, the Americas, and Asia</li></ul><p>If you’d like to discuss how to prototype with functional materials like the Silver Electron ink using our <a href="https://www.voltera.io/products/nova">NOVA</a> materials dispensing system, <a href="https://www.voltera.io/book-a-meeting/nova-demo?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=prototype-production-vfp-functional-inks&utm_content=book-a-meeting">book a meeting</a> to speak with one of our technical representatives.&nbsp;</p>

From Prototype to Production: VFP on Functional Inks

Explore how VFP Ink Technologies designs functional inks that bridge flexible printed electronics prototyping and industrial manufacturing.

<p>Printed circuit board assembly (PCBA) is the process of mounting and soldering electronic components onto a bare printed circuit board (<a href="https://www.voltera.io/blog/breadboards-pcbs-definitions-materials-costs-benefits-applications#What_are_PCBs?">PCB</a>), transforming it into a functional electronic assembly. Whether building a prototype for validation or producing boards at scale, PCB assembly is an essential step that brings design to life.</p><p>There are several ways to assemble a board and each comes with trade-offs. Broadly speaking, teams either outsource assembly to a third-party service or bring it in-house, with manual process or automation. This guide walks you through the most common PCBA options, their workflows, pros and cons, and when each approach makes the most sense.</p><h2>Outsourcing PCB assembly</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68cc6da785c9326ecaed9009_pcba%E2%80%93guide-pick-place-assembled-PCB.webp" loading="lazy" alt="Rows of green printed circuit boards with mounted electronic components in a manufacturing setting" width="auto" height="auto"></div><figcaption>Assembled PCBs</figcaption></figure><p>Outsourcing to an external manufacturer is a common approach for PCB assembly, especially for teams that prioritize professional-grade reliability and economies of scale.</p><p>A widely used option is overseas assembly houses, primarily based in China and Southeast Asia, which specialize in low-cost, high-volume production. These providers typically offer competitive per-unit pricing, though lead times can range from two to four weeks once quoting, communication, assembly, quality control, and international shipping are factored in.</p><p>Alternatively, manufacturers in Europe and North America are more expensive but provide faster communication and shorter shipping distances for their local clients. <br></p><h3>General workflow for outsourced PCB assembly</h3><ol><li>Clients submit necessary files, including:&nbsp; <br><ul><li>Gerber files for PCB layout</li><li>The bill of materials (BOM) for component sourcing</li><li>Component placement lists (CPL) for pick and place operations</li></ul></li><li>Design for manufacturability (DFM) checks and quoting by the service provider&nbsp;</li><li>Parts sourcing, either procured by the supplier based on the BOM or provided by the client</li><li>Fabrication and assembly, including&nbsp; <br><ul><li>PCB fabrication</li><li><a href="https://www.voltera.io/blog/what-is-solder-paste?id=63cabdf9fe0e56ea299d2f6f">Solder paste</a> application</li><li>Automated pick and place of components</li><li>Reflow soldering</li></ul></li><li>Inspection and testing, including manual inspection by technicians, as well as automated optical inspection (AOI), X-Ray inspection</li><li>Packaging and shipping</li></ol><h3>Pros of outsourced PCB assembly</h3><ul><li>Access to high-reliability assembly lines and professional-grade quality control</li><li>Cost-efficient for large volumes</li></ul><h3>Cons of outsourced PCB assembly</h3><ul><li>Vetting and establishing trust with a reliable service provider can be time-consuming</li><li>Long lead times of several weeks with potential delays, where communication and clarification add further drag&nbsp;&nbsp;</li><li>Design revisions during fabrication can be costly if restarting the cycle is required</li><li>Suppliers’ component shortages force engineers to redesign around available parts, causing delays and reducing design agility</li><li>Most services have minimum order quantity (MOQ) requirements that make small runs disproportionally expensive</li><li>Sharing design files can risk intellectual property (IP) exposure and misuse </li></ul><h2>In-house manual assembly</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68cc6dcedf9fe9f0aad43292_pcba%E2%80%93guide-pick-place-manual-assembly.webp" loading="lazy" alt="Technician hand-soldering electronic components onto printed circuit boards" width="auto" height="auto"></div><figcaption>Manual assembly of a PCB</figcaption></figure><p>For early-stage prototyping or very low-volume fabrication, teams often start with manual assembly using tweezers, soldering irons, magnification aids, syringes or stencils, and reflowing via ovens or heat guns.&nbsp;</p><p>The outcome is heavily dependent on the skill and experience of the operator, leading to inconsistent results, particularly with fine-pitch packages.&nbsp;</p><p>Given the high cost of in-house engineering labor, manual assembly is rarely time-efficient, especially when factoring in frequent rework, such as fixing <a href="https://www.autodesk.com/products/fusion-360/blog/solder-bridging-pcb/#:~:text=Solder%20bridging%20101,a%20trace/component%20burning%20up.">solder bridges</a>, <a href="https://www.indium.com/blog/minimizing-tombstoning/">tombstoning</a>, or misaligned parts.&nbsp;</p><p>In practice, even simple prototypes may take hours with manual work, while more complex boards can consume multiple days of effort.</p><h3>Pros of in-house manual assembly of PCBs&nbsp;</h3><ul><li>Full in-house control over the process</li><li>Instant feedback for iteration</li></ul><h3>Cons of in-house manual assembly of PCBs</h3><ul><li>Very difficult or impossible for miniature components and fine-pitch designs, unscalable, error-prone, and subject to inconsistent, unpredictable quality</li></ul><h2>In-house automated pick and place</h2><p>Automated pick and place (PnP) machines bridge the gap between manual assembly and outsourced production. They use feeders, vacuum nozzles, and vision systems to pick and place surface-mount devices (SMDs) quickly and accurately.&nbsp;</p><p>Automated pick and place machines fall into two broad groups:&nbsp;</p><h3>Do-it-yourself and entry-level pick and place machines</h3><p>Do-it-yourself (DIY) and hobbyist-level pick and place machines introduce low-cost, in-house automation, often built on community-contributed hardware and open-source software. Due to this DIY nature, hobbyists benefit from a constantly evolving ecosystem, such as shared designs, 3D-printed feeders, and hardware upgrades.&nbsp;</p><p>However, these DIY machines also present limitations. For example, since they are less structurally rigid than professional systems, the rapid acceleration of the placement head can introduce vibration, thus limiting placement accuracy. In addition, users have noted that achieving consistent performance requires extensive calibration, including tuning motion systems, nozzle offsets, and feeder height, which adds to the setup time significantly.</p><p>Entry-level desktop pick and place machines typically support standard feeders and offer basic features like camera-guided alignment. They can be a practical choice for users experimenting with SMT assembly in-house, providing a step up from manual placement.&nbsp;</p><p>However, the reliability of these DIY and entry-level pick and place machines remains inconsistent, and users frequently note setup frustrations and limitations in usability (i.e. when handling 0402 components). Difficult-to-use programming interfaces, inconsistent feeder performance, and unreliable peeler performance are also frequently mentioned by users.</p><h3>Industrial-grade pick and place machines</h3><p>Industrial-grade pick and place systems are designed for manufacturers to achieve in-line automation. These systems offer high placement speed, large feeder capacity, and high placement accuracy.&nbsp;</p><p>At the top end, full-scale factory equipment is capable of placing tens of thousands of components per hour (CPH) and is integrated with conveyors, solder paste printers, reflow ovens, and inspection systems, enabling end-to-end automation of surface-mount assembly.</p><p>These systems are ideal for continuous, large-scale production environments but are unsuitable for PCB prototyping or small-batch assembly, where their high cost and complex setup requirements outweigh the benefits.</p><h3>Pros of in-house pick and place machines</h3><ul><li>Enables same-day assembly without the need for outsourcing&nbsp;</li><li>Improves repeatability, especially for designs requiring tight tolerances</li><li>Unlocks potential for more complex or densely populated layouts with high-accuracy placement&nbsp;</li></ul><h3>Cons of in-house pick and place machines</h3><ul><li>Incurs high upfront costs from purchasing equipment, with ongoing maintenance overhead&nbsp;</li><li>Lower-tier machines may still struggle with reliability, support, or user experience</li><li>Requires training for programming, setup and calibration</li></ul><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68cc6e561dd8ddba888556bf_pcba%E2%80%93guide-pick-place-industry-pnp.webp" loading="lazy" alt="Automated PCB assembly line with pick-and-place machines and reflow soldering equipment in an electronic manufacturing service (EMS) factory" width="auto" height="auto"></div><figcaption>An industrial SMT assembly line in a factory setting</figcaption></figure><h2>Choosing the right approach</h2><p>There’s no one-size-fits-all method for PCB assembly. Your choice should align with factors such as board volume, design complexity, timeline, budget, resources, and sensitivity around intellectual property.</p><ul><li>Outsourcing: Production volumes or when professional-grade quality is the top priority</li><li>Manual assembly: Very low-volume, one-off prototypes where speed and minimal upfront cost are more important than precision</li><li>Automated pick and place: When fast iteration cycles or IP protection are critical</li></ul><h2>Conclusion </h2><p>PCB assembly is a balancing act between cost, agility, and quality. By understanding and aligning trade-offs with your team priorities, you can turn designs into working boards more efficiently, while staying on time, on budget, and on track for innovation.</p><p>Interested in learning more about PCB prototyping and assembly? Check out these blogs:</p><ul><li><a href="https://www.voltera.io/blog/breadboards-pcbs-definitions-materials-costs-benefits-applications?id=6686c73a133826dbbd656afb">Breadboards vs. PCBs</a>&nbsp;</li><li><a href="https://www.voltera.io/blog/what-is-solder-paste?id=63cabdf9fe0e56ea299d2f6f">What is Solder Paste?</a></li></ul><p>Discover how Voltera is transforming PCB assembly with <a href="https://info.voltera.io/alta-pick-and-place?utm_campaign=31752028-Alta%20Launch&utm_source=website&utm_medium=blog&utm_term=pcba-guide-pick-place-options&utm_content=Alta">Alta</a>, our new desktop pick and place machine designed to streamline in-house prototyping.</p>

What is PCBA? A Guide to Pick and Place Options

Explore PCB assembly (PCBA) options, including outsourcing, manual assembly, and automated pick and place machines. 

What Is PCBA? A Guide to Outsourcing, Manual, and Pick and Place Options

Explore PCB assembly options including outsourcing, manual assembly, and automated pick and place. 

<p><a href="https://www.voltera.io/use-cases/applications/printed-batteries">Printed batteries</a> are one of the key applications of additive electronics. With <a href="https://www.voltera.io/products/nova">NOVA</a>, a materials dispensing system for additive electronics, we printed <a href="https://www.voltera.io/use-cases/white-papers/printing-magnesium-zinc-battery-saral-inks-pet">a seven-layer flexible battery</a> using Saralon’s SaralBattery Inks. In a recent conversation with <a href="https://de.linkedin.com/in/stevepaschky">Steve Paschky</a>, Managing Director at Saralon, we discussed Saralon’s mission, its ink technologies, and how developers can prototype flexible batteries using SaralBattery Inks.</p><h2>About Saralon and its ink offerings</h2><p><strong>Q: Tell us about Saralon and its mission in the field of additive electronics?</strong></p><p>A: Saralon is dedicated to transforming printing companies into electronic manufacturers. Although printed electronics have been known in the scientific community for the last two decades, only a handful of products have reached the market. In other words, we are still scratching the surface of this emerging technology.</p><p>The market potential is enormous, with the ability to impact virtually every aspect of daily life. But to unlock that potential, traditional color-printing companies must be involved. These companies already operate millions of sophisticated, high-speed printing machines around the world — machines that, with the right inks and process know-how, are capable of producing printed electronics.</p><p>Sarlon has accepted this challenge: to localize electronics production by enabling printing companies to manufacture sustainable electronic devices for local demand. The company develops compatible, easy-to-process Saral Inks<sup>©</sup> for screen printing, and has expanded into flexo printing as well as dispensing and inkjet technologies to broaden what’s possible in printed electronics.&nbsp;</p><h2>Benefits of Saralon’s SaralBattery Inks</h2><p><strong>Q: What makes Saralon’s battery ink suite unique and what are the benefits of using it to prototype flexible batteries? </strong></p><p>A: Saralon has developed a new generation of battery ink technology to print Zinc-ZnCl<sub>2</sub>-MnO<sub>2</sub> batteries. This solution addresses not only the concerns of sustainability and cost but also the desire to customize printed battery size, shape, and power specifications in-house.&nbsp;</p><p>SaralBattery Inks are a fully-printable set of compatible functional inks (seven Saral Inks<sup>©</sup>) for prototyping and manufacturing Zinc-ZnCl<sub>2</sub>-MnO<sub>2</sub> batteries on lightweight flexible substrates.&nbsp; They allow printed electronics application developers to customize their printed battery size, shape, and power specifications based on the end-user requirements by changing the size and thickness of the layers or printing them in series. </p><p>Other features include:</p><ul><li>Open circuit voltage of 1.5 V (unit cell)</li><li>Energy density of 0.5-1 mAh/cm<sup>2 </sup>(active area)</li></ul><p>The inks are also compatible with environmentally friendly substrates such as biodegradable paper and recyclable blister foil — an advantage for applications where sustainable, customizable power sources have historically been difficult to achieve, such as wearables, traceable parcels, smart packaging, and other IoT devices.</p><p><strong>Q: How well does Saralon’s battery ink suite scale from prototyping to mass manufacturing?</strong></p><figure class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="http://youtube.com/watch?v=yGCIPTS8Fmc&feature=youtu.be"><div><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/yGCIPTS8Fmc" title="How to mass-produce sustainable batteries by printing!"></iframe></div></figure><p>A: The SaralBattery Inks are fully printable not only on lab scale but also on fully automatic screen printing lines. As the ink suite is compatible with both screen printers and materials dispensing systems, it is suitable for:&nbsp;</p><ul><li>University and research institutions</li><li>R&amp;D departments for IoT device development</li><li>Large-scale production of flexible printed batteries</li><li>Integration of power source into market-ready IoT devices</li></ul><h2>Printed battery applications using SaralBattery Inks</h2><p><strong>Q: Can you share any interesting prototyping projects that have used the Saralon battery ink suite?</strong></p><p>A: SaralBattery Inks have been used across multiple high-value smart markets to produce sustainable power sources for IoT applications.</p><h3>Temperature logger</h3><p>The cold-chain ecosystem involves many stakeholders, making accurate, continuous temperature records essential for accountability and consumer trust. Thin, flexible, and sustainable temperature loggers remove human error and improve data accuracy by recording temperature at set intervals throughout the shipping process.&nbsp;</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/69416b12e4364013390a709e_flexible-printed-battery-applications-temperature-logger.webp" loading="lazy" alt="Gloved hands holding a flexible printed PET sheet containing a temperature-logger circuit. The sheet includes a printed NFC antenna, conductive traces, and multiple rectangular battery layers produced with SaralBattery Inks"></div><figcaption>A temperature logger circuit with built-in battery printed using SaralBattery Inks</figcaption></figure><p><a href="https://emag.ope-journal.com/march-2024/scalable-production-of-self-powered-printed-temperature-loggers-using-functional-inks">This project</a> used SaralBattery Inks for printing the entire circuit in-house, integrating:</p><ul><li>A built-in power source</li><li>A display</li><li>A near field communication (NFC) antenna</li></ul><h3>Wearable sensor (Biomarker)</h3><p><a href="https://www.elsah.researchproject.at/home.php">ELSAH</a> is a five-year smart-patch project that aims to develop an integrated wearable sensor system,&nbsp; the ELSAH-patch, designed for continuous monitoring of molecular biomarker concentrations.</p><p>SaralBattery Inks were used to print a battery that enables the patch’s self-sustained operation, including independent measurements and secure wireless transmission of data to a user’s mobile phone.</p><h2>Additional resources</h2><p>If you’d like to learn more about Saralon’s products or request samples or technical support, you can reach them at <a href="mailto:inks@saralon.com">inks@saralon.com</a> or visit <a href="https://www.saralon.com">their website</a>, where you’ll find detailed information about their functional Saral Inks© and additional innovations, including:</p><ul><li><a href="https://www.saralon.com/en/saral-stretchsilver-ink/">Stretchable printed electronics</a>&nbsp;</li><li><a href="https://www.saralon.com/en/saralink-copper/">Low-cost mass manufacturing through copper ink</a>&nbsp;</li><li><a href="https://www.saralon.com/en/saralink-printedbattery/">Fully printable non-flammable batteries</a></li><li><a href="https://www.saralon.com/en/saralink-oledlabel/">Flexible (ultra-thin) light emitting OLED Labels</a></li></ul><p>Interested in using NOVA for similar printed battery applications? <a href="https://www.voltera.io/book-a-meeting/nova-demo?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=flexible-printed-battery-applications-insights-saralon&utm_content=book-a-meeting">Book a meeting</a> to speak with one of our technical representatives.</p>

Flexible Printed Battery Materials: Saralon Insights

Learn about prototyping flexible printed batteries using Saralon’s SaralBattery Inks and real-world applications of printed batteries in IoT and wearables.

<p id="">In this webinar, <a href="https://www.linkedin.com/in/matthewpchin" id="">Matthew Chin</a>, our Technical Support Specialist, explored how soft robotics benefits from direct ink writing (DIW) technologies like Voltera’s <a href="https://www.voltera.io/products/nova" id="">NOVA materials dispensing system</a> and offered a deep dive into flexible and stretchable materials and substrates used in soft robotics applications.&nbsp;</p><p id="">We were joined by <a href="https://ca.linkedin.com/in/nicholaslevinski" id="">Nick Levinski</a>, Wearable Mechanical Engineer at Proception AI, who introduced the fundamentals of soft robotics and shared hands-on insights from his projects at the University of Waterloo.</p><figure class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=bd6LAg0ae9M"><div><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/bd6LAg0ae9M" title="Webinar: Printing Flexible Electronics for Soft Robotics"></iframe></div></figure><h2 id="">Webinar highlights</h2><h3 id="">Fundamentals and key applications of soft robotics</h3><p id="">Nick opened the session by explaining the core principles of soft robotics — robotic systems made from compliant materials like silicone, fabric, and thermoplastics that move and deform more like muscles than machines.</p><p id="">He covered common actuation strategies, including:</p><ul id=""><li>Pneumatic actuators&nbsp;</li><li>Thermally responsive materials</li><li>Magnetically driven components</li></ul><p id="">Nick then shared a few standout projects from his lab. The first one is a multilayer capacitive gripper built using NOVA with a stretchable TPU substrate. This 3D-printed soft gripper includes printed sensors heat-pressed into fabric for glove integration. The sensor data enables contact detection, paving the way for autonomous grasping.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/692f5e5998faae91bb25dc0f_flexible-electronics-soft-robotics-capacitive-sensor.webp" loading="lazy" alt="A multilayer capacitive sensor printed by NOVA on Intexar™ TE-11C TPU substrate"></div><figcaption>A stretchable multilayer capacitive sensor printed by NOVA</figcaption></figure><p id="">Another interesting project is a lymphedema sleeve with microfluidics. Developed at the <a href="https://uwaterloo.ca/waterloo-microfluidics-laboratory/" target="_blank">Waterloo Microfluids Lab</a>, this wearable sleeve features soft actuators that simulate lymphatic massage therapy. By eliminating bulky valves and solenoids in favor of a passive microfluidic network, the team created a lightweight, portable device aimed at improving patient quality of life.</p><h3 id="">Overview of NOVA and materials for soft robotics</h3><p id="">Next, Matthew introduced NOVA and its empowering role in rapid prototyping of soft robotics. He highlighted several materials used for wearables and soft robotics, all supported by NOVA, including:</p><ul id=""><li><a href="https://store.voltera.io/products/aci-ss1109-stretchable-insulator" id="">ACI SI3104 stretchable insulator</a></li><li><a href="https://store.voltera.io/products/aci-sc1502-2ml-cartridge" id="">ACI SC1502 stretchable carbon ink</a></li><li><a href="https://store.voltera.io/products/aci-fs0142-2ml-cartridge" id="">ACI FS0142 flexible silver ink</a></li><li><a href="https://store.voltera.io/products/aci-fc3203-flexible-carbon-ink" id="">ACI FC3203 flexible carbon ink</a></li><li><a href="https://store.voltera.io/products/vfp-silver-electron-ink-2ml-cartridge-copy" id="">VFP Silver Electron flexible silver ink</a></li><li><a href="https://store.voltera.io/products/vfp-ecv003-2ml-cartridge-copy" id="">VFP ECV003 green-tinted dielectric varnish</a></li><li><a href="https://store.voltera.io/products/intexar-tpu-5-sheets" id="">Intexar™ TE-11C TPU substrate</a></li><li><a href="https://store.voltera.io/products/pet-5-sheets">Normandy Coating Arcophane AA STS PET substrates</a></li></ul><p id="">These materials are available on our store, with <a href="https://store.voltera.io/collections/materials?filter.p.m.custom.product_type=Bundles" id="">bundle</a> discounts for those looking for affordable and hassle-free options.&nbsp;</p><h2 id="">Live Q&amp;A</h2><h3 id="">Soft robotics projects</h3><p id=""><strong id="">Q</strong>: What is the maximum bending angle of the printed substrates on the robotic gripper?</p><p id=""><strong id="">A</strong>: Instead of a maximum bending angle, it’s more useful to think about minimum bend radius. For a 100-150 µm substrate, the minimum bend radius is typically around one millimeter (five to ten times the thickness). For the soft robotic gripper, the bending angle can reach around 100° in ideal cases. Nick tested fold lines, but achieving a clean crease was difficult. The bend radius became smaller than one millimeter unless we used a metal dowel to maintain it. However, that created a less desirable form factor, so we didn’t proceed with that approach.</p><p id=""><strong id="">Q</strong>: Can you elaborate on the computation used in the soft robotic system with flexible electronics? How complex is it, and what are the hardware constraints?</p><p id=""><strong id="">A</strong>: A practical approach is to build a simplified model of the soft robot that can run on-device (edge computing). This typically involves a linear approximation of how the robot deforms under a given pressure or current, combined with a feedback loop from embedded sensors and a basic control method (e.g., a proportional controller). Full physics-based finite element method (FEM) simulation of soft robots in real time is not yet feasible, though companies like NVIDIA are exploring it. For hardware complexity, the constraints depend on the application:</p><ul id=""><li>Wearables prioritize minimizing footprint, weight, and wired connections, often requiring wireless modules with strict power limits.</li><li>Robotic arms can rely on wired connections and external compute modules, making power and footprint less restrictive.</li></ul><p id=""><strong id="">Q</strong>: What was the substrate of the printed silver used on the soft robotic gripper? Was it attached thermally?</p><p id=""><strong id="">A</strong>: Nick used <a href="https://store.voltera.io/products/intexar-tpu-5-sheets" id="">Intexar TE-11C</a>, attached using a heat‑press process (similar to a standard apparel heat press). When pressed onto a compatible fabric, it forms a strong thermal bond that resists delamination.</p><p id=""><strong id="">Q</strong>: Do sensors behave linearly? Can we rely on them for repeatable results, and how does fatigue affect performance?</p><p id=""><strong id="">A</strong>: Most soft sensors do not behave linearly. Their response is often inverse-square, logarithmic, or exponential, so they require calibration to achieve a linear approximation. Repeatability depends on:</p><ul id=""><li>Strain and stress levels</li><li>Material hysteresis</li><li>Ink formulation</li><li>Substrate deformation (e.g., plastic deformation at high strain)</li><li>Actuation speed vs. material relaxation time</li></ul><p id="">Pushing the materials too far reduces repeatability.</p><h3 id="">Printing with NOVA</h3><p id=""><strong id="">Q</strong>: What is the curing process of the inks on your online store?</p><p id=""><strong id="">A</strong>: Most of these inks are cured in a box oven at temperatures above 100°C for 5-15 minutes, depending on the formulation (refer to each ink’s <a href="https://docs.voltera.io/docs/v-one/downloads/safety-data-sheets" id="">data sheet</a>). For multilayer printing, each layer must be cured before printing the next one, especially when changing materials, to prevent mixing.</p><p id=""><strong id="">Q</strong>: Can inks be printed on glass, and has adhesion been proven?</p><p id=""><strong id="">A</strong>: Yes, some inks are formulated specifically for glass and ceramic substrates. Adhesion performance is provided in the manufacturer’s technical data sheet, along with any supporting test data. Consult the data sheet for the specific ink you're using.</p><p id=""><strong id="">Q</strong>: Are there inks suitable for flexible materials requiring curing below 100°C? Are there alternative curing options?</p><p id=""><strong id="">A</strong>: Yes. Some inks are designed for lower‑temperature curing, and many inks can be cured at lower temperatures over longer times while still achieving functional performance. This is often how we handle temperature‑sensitive substrates.</p><p id=""><strong id="">Q</strong>: Are there conductive inks and substrates that are biocompatible? For example, for implanted devices?</p><p id=""><strong id="">A</strong>: Some inks are biocompatible, such as silver-silver chloride inks designed for skin-contact applications (e.g., wearable heart-rate monitors). However, most are intended for surface or on-skin applications, not long-term implanted devices. Always check the ink’s data sheet for biocompatibility information.</p><p id=""><strong id="">Q</strong>: Are the inks on your online store only suitable for NOVA? Can they be used for spin coating or spray coating on TPU?</p><p id=""><strong id="">A</strong>: These inks are not exclusive to NOVA. They are primarily designed for screen printing, and NOVA provides a way to prototype with them without screens.&nbsp;</p><ul id=""><li>Spin coating: not suitable because the viscosity is too high.</li><li>Spray coating: generally unsuitable for the same reason.</li><li>Screen printing: fully supported and ideal for production.</li></ul><p id=""><strong id="">Q</strong>: Are there restrictions on surface roughness when printing on substrates?</p><p id=""><strong id="">A</strong>: Generally, surface roughness is not an issue. The nozzle prints about 60 µm above the surface, so printing quality is maintained. For very rough surfaces, you may need to deposit extra material to fill surface valleys. In normal use cases, roughness does not cause problems.</p><p id=""><strong id="">Q</strong>: Is there a way for research institutions to test their inks on NOVA as part of collaborations?</p><p id=""><strong id="">A</strong>: Yes. We offer printing as a service, and we have tested external inks to assess NOVA compatibility.If you have a custom ink you'd like evaluated, <a href="https://www.voltera.io/book-a-meeting/printing-service?" id="">contact our sales team</a> and they will guide you through the submission process.</p><h2 id="">Bonus for attendees</h2><p id="">As a thank-you, we have a discount code in the <a href="https://www.youtube.com/watch?v=bd6LAg0ae9M" id="">webinar video</a> for people interested in soft robotics.</p><h2 id="">Additional resources</h2><p id="">Want to learn more about soft robotics and wearable electronics? Check out these resources:</p><ul id=""><li>White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" id="">Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control</a></li><li>Video: <a href="https://youtu.be/EZNg21U0loE" id="">Printing Silver Conductive Ink on Cotton Fabric</a></li><li>Keynote: <a href="https://www.youtube.com/watch?v=hKK7YWAN46U&t" id="">ECG Sensors Printed with Gold | Voltera Keynote at TechBlick Printed Electronics Innovation Day 2024</a></li></ul><p>Ready to talk about how NOVA can be used for your wearable or soft electronics application? <a href="https://www.voltera.io/book-a-meeting/nova-demo?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-flexible-electronics-soft-robotics&utm_content=book-a-meeting" id="">Book a meeting </a>to speak with one of our technical representatives.</p>

Webinar Recap: Printing Flexible Electronics for Soft Robotics

In this webinar, we explored soft robotics and how NOVA enables rapid prototyping of wearable soft electronics built with flexible and stretchable materials.

<p id="">In this webinar, Nathan Shinkar, our Support Lead, demonstrated how the V-One PCB printer and a series of hands-on project kits help educators bridge the gap between electronics theory and real-world circuit design.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=pBu8xEaSmG4"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/pBu8xEaSmG4" title="Webinar: Hands-On PCB Education - Bridging Theory and Practice in the Classroom"></iframe></div></figure><h2 id="">Webinar highlights</h2><h3 id="">Bringing circuits to life in the classroom</h3><p id="">These projects are designed for teaching electronics.The new educational kits include:</p><ul id=""><li id=""><a href="https://store.voltera.io/products/voltage-regulator-kit" id="">Voltage regulator kit</a> – converts 7V-12V to 5V using both linear and switching regulator ICs.</li><li id=""><a href="https://store.voltera.io/products/pulse-generator-kit" id="">Pulse generator kit</a> – uses a 555 timer in astable mode with a variable resistor to produce adjustable timing signals.</li><li id=""><a href="https://store.voltera.io/products/99-decimal-counter-kit" id="">99 decimal counter kit</a> – uses binary-coded decimal counters and decoders to drive a pair of 7-segment displays from pulse inputs.</li></ul><p id="">The session featured a live board print on the V-One using Voltera’s silver ink, <a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml" id="">Conductor 3</a>, covering probing, alignment, calibration, and printing. Attendees got a close look at the software workflow and hardware setup, along with a final demonstration of all three kits operating in sequence.</p><h3 id="">Teaching electronics with V-One</h3><p id="">Nathan shared how each kit builds foundational knowledge while introducing core circuit design principles, including:</p><ul id=""><li id="">Voltage drop, efficiency, and thermal management in regulator circuits</li><li id="">Capacitor charging and pulse width control in 555-based timers</li><li id="">Binary and decimal logic through hardware-based counting</li></ul><p id="">The kits offer scalable learning paths: from simple assembly and observation, to schematic analysis, to full custom board design in ECAD software. All kits come with step-by-step documentation available on <a href="https://docs.voltera.io/docs/v-one/learn-v-one/v-one-projects" id="">our Support site</a>.&nbsp;</p><p id="">Beyond the kits, V-One enables students to explore additive manufacturing concepts like conductive ink printing, solder paste dispensing, curing, reflow, and even via drilling — all within a safe and clean desktop workflow.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/69287006f0b8033532974052_webinar-recap-pcb-education-live-printing.webp" loading="lazy" alt="Close-up of the V-One PCB printer dispensing silver ink onto a black FR1 substrate during a live print of the voltage regulator circuit, with the nozzle mid-trace and clamps in view" width="auto" height="auto" id=""></div><figcaption id="">V-One printing the voltage regulator circuit live</figcaption></figure><h2 id="">Live Q&amp;A</h2><p id=""><strong id="">Q</strong>: How many layers can V-One print?</p><p id=""><strong id="">A</strong>: V-One supports double-sided PCBs by drilling through holes to make vias.&nbsp;</p><p id=""><strong id="">Q</strong>: What’s the smallest trace and gap V-One supports?</p><p id=""><strong id="">A</strong>: 200 µm trace width and spacing, using metal nozzles for higher precision.</p><p id=""><strong id="">Q</strong>: How do you mount components such as SMD or through holes?</p><p id=""><strong id="">A</strong>: SMD components are reflowed on-board, and through-holes can be drilled and soldered manually.</p><p id=""><strong id="">Q</strong>: Is this printer designed solely for educational purposes or can it also be used as a prototyping and production tool?</p><p id=""><strong id="">A</strong>: V-One was designed for speeding up prototyping and turned out to be a great tool for education as well. For production, it depends on the volume. It’s possible to use V-One for low-volume production, but V-One is not designed for mass production.</p><p id=""><strong id="">Q</strong>: Does the printer have a resume option if any power cut happens?</p><p id=""><strong id="">A</strong>: No. V-One does not currently support automatic resume after a power failure. It’s recommended to ensure a stable power source during printing.</p><p id=""><strong id="">Q</strong>: What is the difference between a plastic and metal nozzle and which should I use?</p><p id=""><strong id="">A</strong>: Metal nozzles offer better precision and are ideal for fine features like 0.2 mm traces, but they’re more expensive. Plastic nozzles are more affordable and suitable for general use, though they often need to be replaced after each print. If high accuracy isn’t critical, plastic nozzles are usually sufficient.</p><h2 id="">Additional resources</h2><p id="">Want to learn more about PCB education? Check out these resources:</p><ul id=""><li id="">Webinar: <a href="https://youtu.be/h5EiL5QOOO0?si=JVNzzlooVNjy901O" id="">Printing PCBs for Hands-On Learning</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-decimal-counter-circuit-silver-conductive-ink-fr1" id="">Printing a Decimal Counter Circuit with Silver Conductive Ink on FR1</a></li><li id="">Project guide: <a href="https://docs.voltera.io/docs/v-one/learn-v-one/v-one-projects/voltage-regulator-project" id="">Voltage Regulator Project</a></li><li id="">Customer story:<a href="https://www.voltera.io/use-cases/customer-stories/itiz-revolutionizing-engineering-education-v-one" id=""> Revolutionizing PCB Design Education with V-One</a></li></ul><p id="">Ready to talk about how V-One can be used for your application? <a href="https://www.voltera.io/book-a-meeting/v-one-call?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-hands-on-pcb-education&utm_content=book-a-call" id="">Book a call</a> to speak with one of our technical representatives.</p>

Webinar Recap: Hands-On PCB Education

In this webinar, we explored hands-on PCB education using V-One and new Voltera circuit kits to teach voltage regulation, timing, and digital counting.

<p id="">Have you ever had food poisoning from eating spoiled food? It may seem harmless to test food quality by taking a small bite, or perhaps you were unaware of the dangers of the food you ate. Regardless, the results are never pleasant. Symptoms can range from stomach pain and vomiting to fevers and dehydration. Food poisoning is often an acute and serious condition.</p><p id="">The good news is researchers at the Universitat Politècnica de Catalunya, one of our customers based in Barcelona, Spain, recently published a study [1] featuring a flexible resonator that monitors dielectric changes in meat — a promising step toward smarter, safer food quality testing.</p><h2 id="">Developing a meat freshness sensor</h2><p id="">Scientists set out to develop a resonator that is capable of monitoring meat freshness in real time by detecting dielectric property changes as the meat degrades. To achieve that, they needed to design a low-cost, printable, and non-invasive radio frequency (RF) sensor that operates within the 2.4 GHz ISM band, providing accurate, repeatable measurements for food quality monitoring and potential IoT integration.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6903752cbad3066ca0523728_printing-smart-resonator-meat-monitor-antenna.webp" loading="lazy" alt="Diagram showing comprehensive experimental setup for analyzing dielectric property variations in meat samples from Day 0 to Day 5. The left panel shows visual changes in meat color and texture over time with progressive spoilage. The right panel depicts a measurement system using a vector network analyzer (VNA), loop antenna, tripod, and foam platform, with data processing displayed on a monitor." width="auto" height="auto" id=""></div><figcaption id="">Monitoring system set up for tracking meat freshness © <a href="https://doi.org/10.3390/s25051338" target="_blank">Abounasr, J. et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><h3 id="">How it works</h3><p id="">The resonator is a loop antenna-based sensor that generates a localized electromagnetic field. When a meat sample is placed near it, the changing permittivity (dielectric constant) of the meat affects the antenna’s impedance and resonant frequency.&nbsp;</p><p id="">As spoilage progresses, the dielectric properties shift, causing the resonance to drop from 2.14 GHz (Day 0) to 1.29 GHz (Day 5). This frequency shift directly correlates with meat freshness and can be measured using a vector network analyzer (VNA).</p><h3 id="">Fabrication process&nbsp;</h3><p id="">The sensor was printed on a flexible polyimide (Kapton) substrate using Voltera’s <a href="https://www.voltera.io/products/nova" id="">NOVA materials dispensing system</a>, an additive platform designed to prototype flexible hybrid electronics (FHE) like flexible sensors. NOVA’s vacuum table helps researchers secure their flexible substrate onto the platform for automatic heat mapping and during the printing process. Its ink pressure sensing and temperature-controlled dispensing enabled rapid and consistent printing of conductive silver traces.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/690375316f7de7b8a2441d9e_printing-smart-resonator-flexible-antenna-nova.webp" loading="lazy" alt="Close-up of a circular loop antenna sensor with a marked sensing area at the center, printed on a flexible polyimide substrate" width="auto" height="auto" id=""></div><figcaption id="">The flexible antenna printed on polyimide with NOVA © <a href="https://doi.org/10.3390/s25051338" target="_blank">Abounasr, J. et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">After printing, the antenna was oven-cured at 50°C for 15 minutes to ensure strong adhesion and stable conductivity. This process produced a compact (50 × 70 mm) resonator with reliable electrical conductivity (50 Ω impedance).</p><h3 id="">Results</h3><p id="">Over six days of testing, the resonator consistently tracked dielectric changes in beef samples, showing a linear correlation between frequency shifts and meat degradation. The system demonstrated average sensitivity of 0.173 GHz/day, low standard deviation, and excellent reproducibility across multiple samples. Simulations confirmed that as meat permittivity increased from about 37 to 91, the resonant frequency decreased proportionally, matching experimental trends.&nbsp;</p><h2 id="">Conclusion</h2><p id="">The study demonstrated that this flexible loop antenna offers a low-cost, reliable method for real-time, non-invasive monitoring of food quality, with strong potential for IoT-based food safety systems and other perishable goods.&nbsp;</p><p id="">Interested in seeing other Voltera customer innovations? Check out the following resources:</p><ul id=""><li id="">Customer story: <a href="https://www.voltera.io/use-cases/customer-stories/polytechnique-montreal" id="">Researching Printed Stretchable Bioelectronics with Voltera NOVA and V-One</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/advancing-printed-sensors-rfid-tag-breath-monitoring" id="">Advancing Printed Sensors: RFID Tag for Breath Monitoring</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/ai-powered-ingestible-sensor-monitoring-gut-health" id="">AI-Powered Ingestible Sensor for Monitoring Gut Health</a></li></ul><p id="">Ready to talk about prototyping flexible printed sensors with NOVA? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=printing-smart-resonator-track-meat-freshness&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">References</h2><p id="">[1] Abounasr, J., Gharbi, M. E., Raúl Fernández García, &amp; Gil, I. (2025). A High-Sensitivity Inkjet-Printed Flexible Resonator for Monitoring Dielectric Changes in Meat. <em id="">Sensors</em>, 25(5), 1338–1338. <a href="https://doi.org/10.3390/s25051338" id="">https://doi.org/10.3390/s25051338</a>.</p>

Printing a Smart Resonator to Track Meat Freshness

Learn how researchers at Universitat Politècnica de Catalunya printed a flexible sensor that detects meat spoilage through dielectric property changes.

<p id="">Just like any type of project, the first step of printed circuit board (PCB) prototyping is ideation, where you define the core functionality and components of your circuit. If PCBs serve as the “brains” behind nearly all electronic systems, then designing the board is like meticulously mapping the brain's neural pathways. You are drawing the intricate arteries and veins that will carry power and signals, enabling the entire system to think and function.</p><h2 id="">Workflow of designing a PCB</h2><p id="">The exact workflow can vary with project needs, but generally it involves defining the project requirements, choosing components, and drawing the schematic. This is followed by setting up component placement and routing the conductive traces in a PCB layout tool.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68dd3cbf9a460307c3ddaada_design-printed-circuit-board-pcb-workflow.webp" loading="lazy" alt="Workflow diagram illustrating the four main steps of printed circuit board design: step 1 — define requirements, step 2 — schematic capture, step 3 — circuit simulation, and step 4 — layout design." width="auto" height="auto" id=""></div><figcaption id="">The workflow of designing a printed circuit board</figcaption></figure><p id="">Once the layout is complete, the final steps include running design rule checks (DRC), generating manufacturing files (like Gerbers), and importing the files into a PCB printer’s software, like the <a href="https://www.voltera.io/products/v-one" id="">V-One</a> software, to <a href="https://www.voltera.io/blog/prototype-pcbs-in-house" id="">prototype the physical board</a>. Alternatively, if you’re outsourcing to a PCB manufacturer, you’ll need to upload the files to their website, communicate your requirements, and wait for the finished boards to be shipped.</p><h2 id="">Defining project requirements</h2><p id="">Every PCB design begins with a clear definition of the project requirements and constraints. At this stage, the goals and specifications of the circuit are determined based on the intended application and environment.&nbsp;</p><p id="">Important considerations include:</p><ul id=""><li id="">Functionality of the circuit, such as <br><ul id=""><li id="">Signal processing</li><li id="">Power delivery</li><li id="">Microcontroller logic</li></ul></li><li id="">Performance metrics that influence component choices and layout (e.g., low-level amplifier circuits have special needs for well-placed microstrip interconnections [1].)</li><li id="">Environmental constraints, such as&nbsp; <br><ul id=""><li id="">Size and form factor of the board</li><li id="">Ambient temperature range</li><li id="">Expected mechanical stresses</li><li id="">Any enclosure that the PCB must fit into</li></ul></li><li id="">Regulatory standards or certifications like electromagnetic interference (EMI) regulations and safety standards that the design must comply with</li><li id="">Budget, which can affect component selection and board complexity.</li></ul><p id="">With these requirements, you’ll be able to select specific components for each function. <a href="https://www.ni.com/en/solutions/design-prototype/pcb-design-fundamentals--prototyping-and-the-pcb-design-flow.html#section--1876515770" id="">It’s recommended</a> to consult datasheets and supplier catalogs, and you may want to use manufacturer simulation tools to evaluate components.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68dd3ce9db745dc0afd9c9f1_design-printed-circuit-board-pcb-schematic.webp" loading="lazy" alt="Circuit schematic of a pulse generator using an NE555 timer IC, with connected resistors, capacitors, power supply, test point, and LED output." width="auto" height="auto" id=""></div><figcaption id="">A schematic design for a pulse generator circuit</figcaption></figure><p id="">With clear requirements and a concept in mind, the next step is to design the circuit schematic. Schematic capture means creating a diagram that shows all electronic components and how they are electrically connected with nets according to the circuit logic.</p><p id="">You might have drawn a circuit schematic with a paper and pencil before, but to streamline PCB development, you’ll need to design it digitally with electrical computer-aided design (ECAD) software, or electronic design automation (EDA) software.</p><p id="">Using ECAD software offers numerous advantages:</p><ul id=""><li id="">Digital files are inherently cleaner and easier to modify than hand-drawn, erased papers.</li><li id="">All professional ECAD tools include DRC to flag errors like unconnected wires (opens) or incorrectly spaced traces.</li><li id="">It’s easy to transition from a schematic to a PCB layout within the software.</li><li id="">Component libraries store component footprints and symbols.</li></ul><h3 id="">Choosing your ECAD software</h3><p id="">There are many EDA software options available. While commercial packages excel in large-team environments and complex design rule management, free or open-source tools like KiCad provide robust capabilities at no cost, which is ideal for individuals or schools on a budget.&nbsp;</p><h4 id="">Commonly used ECAD software</h4><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/68dd3d402b28c722094d61bd_1c6c71e3ee750fdfc6fbb39c8530628f_Blog_Design%20PCB_table%201.txt[/script]</p><h3 id="">Best practices for drawing schematics</h3><p id="">When drawing a PCB schematic, it is important to indicate all connections clearly, including power rails and ground references. It’s also recommended to organize the schematic logically (grouping related components into sections, using labels for nets) so that it’s easy to review and understand.&nbsp;</p><p id="">At this stage, designers also assign reference designators to components (U1 for the first IC, R1 for the first resistor, etc.) and ensure each component’s symbol is linked to the correct physical footprint.</p><p id="">It also helps to plan ahead for trace widths — especially for power and ground lines, which should be wider to reduce resistance and handle current more safely. Wider traces are also more durable for hand soldering. If unsure, you can estimate appropriate widths with tools like this <a href="https://circuitcalculator.com/wordpress/2006/01/31/pcb-trace-width-calculator/" target="_blank" id="">PCB trace width calculator</a>.</p><h2 id="">Circuit simulation</h2><p id="">Before committing the design to a PCB layout, it’s often beneficial to simulate the circuit or otherwise verify its behavior [1]. Many ECAD tools like KiCad have built-in simulation support, which enables designers to check things like amplifier gains, filter responses, signal integrity, or power supply stability.</p><h2 id="">PCB layout design</h2><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68dd3d942ac1fffc37596014_design-printed-circuit-board-pcb-layout.webp" loading="lazy" alt="PCB layout of an NE555-based pulse generator circuit, showing traces, resistors, capacitors, diode, and connection points for +5V, ground, and output pulse" width="auto" height="auto" id=""></div><figcaption id="">PCB layout for a pulse generator circuit</figcaption></figure><p id="">Once the schematic is finalized and verified, the design moves into the PCB layout stage. In general, a completed schematic is transferred to the PCB layout tool, carrying over all components and the netlist. Many ECAD tools like KiCad allow synchronizing or updating the PCB from the schematic, ensuring consistency between them. This is where the abstract schematic is turned into a concrete board design. This involves a few steps:</p><ol id=""><li id="">Board setup: Based on the earlier requirements and any mechanical constraints, the designer defines the PCB dimensions and layer stackup.</li><li id="">Component placement: Components are imported into the layout, each represented by a footprint that specifies the pads or holes where the part will be soldered.</li><li id="">Routing traces: According to the schematic netlist, conductive traces that connect the component pins are drawn, adding through-holes that allow a trace to jump from one layer to another as needed.</li></ol><h2 id="">Refinement</h2><p id="">After completing the layout, designers perform a comprehensive design rule check using the ECAD software. This includes checking that no traces are too close, no copper features violate spacing or size constraints, and there are no unintended overlaps or copper islands. If the DRC finds errors, they should be addressed before exporting the finalized board design for production.</p><h2 id="">Conclusion</h2><p id="">The complete workflow of PCB design incorporates a lot of quality check steps, which are essential for the success of the board. By organizing the process into clear steps and addressing important considerations at each stage, PCB designers can transform an idea on paper into a working PCB without surprises.</p><p id="">Interested in learning more about PCB design? Check out these resources:</p><ul id=""><li id="">Customer story: <a href="https://www.voltera.io/use-cases/customer-stories/itiz-revolutionizing-engineering-education-v-one" id="">Revolutionizing PCB Design Education with V-One</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-decimal-counter-circuit-silver-conductive-ink-fr1" id="">Printing a Decimal Counter Circuit with Silver Conductive Ink on FR1</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/autodesk-voltera" id="">Autodesk ❤ Voltera</a></li></ul><p id="">Want to explore PCB prototyping with V-One? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=design-printed-circuit-board-pcb&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">References</h2><p id="">[1] Scherz, P., &amp; Monk, S. (2016). <em id="">Practical Electronics for Inventors, Fourth Edition</em>. O’Reilly Online Learning. <a href="https://www.oreilly.com/library/view/practical-electronics-for/9781259587559/" id="">https://www.oreilly.com/library/view/practical-electronics-for/9781259587559/</a>.</p>

How to Design a Printed Circuit Board (PCB)

Wondering where to start with designing a circuit? Explore the workflow of designing a printed circuit board, choosing ECAD software, layout design, and more.

<p id="">In this webinar, Voltera’s Applications Technician, <a href="https://ca.linkedin.com/in/devon-pianosi" id="">Devon Pianosi</a>, and Panasonic’s Project Engineer, <a href="https://ca.linkedin.com/in/simonwsm" id="">Simon Wong</a>, explored connector technologies and design strategies for integrating reliable connections into flexible hybrid electronics (FHE). The session covered failure modes, substrate compatibility, material selection, connector classifications, and real-world integration examples using the <a href="https://www.voltera.io/products/v-one" id="">V-One PCB printer</a> and <a href="https://www.voltera.io/products/nova" id="">NOVA materials dispensing system</a>.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=qaZRC9BQ1R0"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/qaZRC9BQ1R0" title="Webinar: How to Connect Circuits - Connector Technologies and Integration Strategies for Electronics"></iframe></div></figure><h2 id="">Webinar highlights</h2><h3 id="">Why connector strategy matters in FHE</h3><p id="">Connector integration is often overlooked in early-stage hardware development, but for flexible and stretchable circuits, it’s one of the most common failure points. The session began with an overview of the mechanical and electrical challenges faced when connecting rigid and flexible circuit elements, especially on substrates like <a href="https://store.voltera.io/products/intexar-tpu-5-sheets" id="">thermoplastic polyurethane</a> (TPU) or <a href="https://store.voltera.io/products/polyimide-5-sheets" id="">polyimide</a> (Kapton).</p><p id="">To reduce risks like tearing, delamination, or cracking near interconnects, it’s important to consider:</p><ul id=""><li id="">Material compatibility between substrate, ink, and adhesives</li><li id="">Placement of connectors to minimize mechanical stress</li><li id="">Use of stiffeners, encapsulation, or cushioning backers to prevent fatigue</li></ul><p id="">Devon shared multiple examples of connector integration, demonstrating how printed flex cables, carbon sensors, and soft stretchable traces can be reliably bonded using zero insertion force (ZIF), crimp, insulation displacement contact (IDC), or anisotropic conductive adhesives.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6895fe33896b3e9d414f76f6_connecting-flexible-circuits-pcb-flex-rigid.webp" loading="lazy" alt="A flexible hybrid electronics prototype on a green cutting mat, featuring an Arduino Nano connected to various flexible sensors and ribbon cables on a custom-printed circuit board." width="auto" height="auto" id=""></div><figcaption id="">Different types of connectors for connecting circuits</figcaption></figure><h3 id="">Types of connectors and use cases</h3><p id="">Simon provided a deep dive into industry-standard connector types, including:</p><ul id=""><li id="">Card edge connectors for power boards and swappable modules</li><li id="">Flat cable and flexible flat cable (FFC) connectors for compact board-to-board links</li><li id="">Two-piece stacking connectors with narrow pitch for vertical orientation</li><li id="">ZIF connectors for flexible PCBs and low-cycle mating applications</li></ul><p id="">For each category, design considerations such as insertion force, retention mechanism, soldering method, and pitch size were addressed. Panasonic’s <a href="https://industry.panasonic.com/global/en/products/control/connector/toughcontact" target="_blank" id="">“Tough Contact” series</a> was highlighted for applications requiring high reliability, corrosion resistance, or miniature footprints.</p><h2 id="">Live Q&amp;A&nbsp;</h2><p id=""><strong id="">Q</strong>: Do crimp connectors work on stretchable circuits?</p><p id=""><strong id="">A</strong>: Yes, with added stiffeners or adhesives to prevent fatigue at the contact point.</p><p id=""><strong id="">Q</strong>: What's the minimum supported pitch for ink traces and connector integration?<br><strong id="">A</strong>: NOVA supports trace widths down to 100 µm, with 0.35-0.5 mm pitch connectors being feasible using fine particle inks.</p><p id=""><strong id="">Q</strong>: Can I glue connectors onto flex boards using Voltera printers?<br><strong id="">A</strong>: You can with NOVA. NOVA dispenses adhesives precisely for automation and connector bonding.</p><p id=""><strong id="">Q</strong>: Are there high-voltage connector options?<br><strong id="">A</strong>: <a href="https://na.industrial.panasonic.com/products/connectors/automotive/lineup/automotive-connectors/series/148005" target="_blank" id="">Panasonic’s CF series</a> offers surface-mountable high-voltage connectors (about 1100-1400 V dielectric strength).</p><p id=""><strong id="">Q</strong>: What are some common beginner mistakes in connector design?<br><strong id="">A</strong>: Common mistakes include not reinforcing connectors, assuming rigid PCB rules apply to flex/stretchable designs, or using low-quality components that skew results.</p><p id=""><strong id="">Q</strong>: Do you have any experience with polydimethylsiloxane (PDMS) or soft substrates?<br><strong id="">A</strong>: We have tested stretchable polymers like TPU and Panasonic's BEYOLEX™ on NOVA, but PDMS integration is still experimental.</p><h2 id="">Additional resources</h2><p id="">Want to learn more about interfacing flexible and rigid circuits? Check out these white papers:</p><ul id=""><li id=""><a href="https://www.voltera.io/use-cases/white-papers/connecting-flexible-stretchable-substrates-printed-circuit-boards" id="">Connecting Flexible and Stretchable Substrates to Printed Circuit Boards</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet" id="">Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" id="">Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="">Printing a Flexible PCB with Silver Ink on PET</a></li></ul><p id="">Ready to talk about how Voltera can help you with your electronics projects? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-connnect-circuits&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p>

Webinar Recap: How to Connect Circuits

In this webinar, we partnered with Panasonic to dive into connector technologies and FHE design strategies — from breakout boards to ZIF and crimp connectors.

<p>Printed circuit boards (PCBs) serve as the “brains” behind nearly all electronic systems, from lighthearted <a href="https://www.youtube.com/watch?v=xoxhDk-hwuo" target="_blank">pranks on package thieves</a> to <a href="https://www.voltera.io/blog/fully-3d-printed-carbon-nanotube-field-emission-electron-sources-with-in">high-stakes carbon nanotube field-emission electron source</a>. Fortunately, designing a PCB is more accessible than you might expect and does not require an engineering degree. The key is knowing how to begin with your circuit’s requirements and translate them into a prototype.</p><h2>Requirement analysis and circuit design</h2><p>Every PCB project begins with careful requirement gathering and circuit design. This involves determining the electrical needs (power levels, signal speeds, component types) and translating them into a schematic. Modern electronic design automation (EDA) software (e.g. KiCad, Eagle), also known as electronic computer-aided design (ECAD) software, makes it straightforward to draw schematics and lay out PCBs.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c038bd13720e1a00d9a606_prototype-pcbs-in-house-circuit-layout.webp" loading="lazy" alt="Digital PCB layout for the &quot;Voltera Punk Console&quot; showing green conductive traces, vias, and component pads on a black grid background" width="auto" height="auto"></div><figcaption>A PCB layout designed by Voltera</figcaption></figure><p>At this stage, you’ll need to capture the circuit logic in a schematic, design the PCB layout, and plan the placement of your conductive traces and components (e.g., adequate trace widths, component footprints, and clearances). Once the design is ready, it can be exported to standard Gerber files for PCB fabrication.</p><h2>Constructing the circuit</h2><p>For small-volume prototypes, you can either build the circuit on a breadboard or fabricate a PCB. The choice depends on factors like needed circuit complexity, frequency, durability, available tools, time, and budget. For more information on their differences, check out this article on <a href="https://www.voltera.io/blog/breadboards-pcbs-definitions-materials-costs-benefits-applications">breadboards vs. PCBs</a>.</p><h3>Breadboard prototyping</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c038f6b64b89a0865ba9a3_prototype-pcbs-in-house-breadboard-ic.webp" loading="lazy" alt="Breadboard-based electronics prototype featuring a development board, an accelerometer sensor, OLED display and an SD card module" width="auto" height="auto"></div><figcaption>A breadboard with components</figcaption></figure><p>A reusable plastic board with spring-loaded contacts, a breadboard facilitates quick circuit assembly without solder. This temporary platform is invaluable for early testing and learning.</p><p>However, prototyping with breadboards comes with certain limitations:</p><ul><li>Parasitic capacitance and inductance in the wiring make it unsuitable for high-speed or RF circuits [1][2].</li><li>Breadboards are designed for through-hole components, but as the industry moves towards surface-mount (SMT) packages, through-hole equivalents become harder to find and more expensive [1].</li><li>Reliability issues can arise as contacts loosen or oxidize over time [1].</li></ul><h3>Additive methods for PCB prototyping</h3><p>When looking for a more permanent and higher performance solution, custom PCB prototyping, particularly additive methods, becomes attractive.&nbsp;</p><p>Additive fabrication builds conductive patterns directly onto a substrate rather than etching or removing copper. This typically involves two steps:</p><ol><li>Printing conductive traces</li><li>Curing conductive traces</li></ol><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c0391b673bf98602a96a2f_prototype-pcbs-in-house-diw-printer.webp" loading="lazy" alt="Close-up of Voltera’s V-One PCB printer dispensing conductive traces onto an FR1 substrate, aligned with pre-drilled through-holes." width="auto" height="auto"></div><figcaption>V-One PCB printer printing conductive material on an FR1 substrate</figcaption></figure><p>In practice, creating additive PCB prototypes often means using specialized tools to directly print <a href="https://www.voltera.io/blog/conductive-inks">conductive material</a> onto a substrate. A great example is a desktop <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">direct ink writing</a> (DIW) machine, like the<a href="https://www.voltera.io/products/v-one"> Voltera V-One PCB printer</a>.&nbsp;</p><p>It can dispense silver ink and solder paste on materials like FR1 and FR4, enabling both the creation of conductive traces and the assembly of components, all on one machine. Depending on design complexity, you can go from digital design to an assembled PCB in under an hour.</p><h4>Benefits of additive PCB prototyping</h4><ul><li>They achieve high accuracy for prototyping needs, resulting in comparable performance to a traditional etched board for practical purposes [3].</li><li>You save precious materials since you only deposit material where needed.</li><li>It is more eco-friendly and suitable for lab environments since you don’t need multiple baths of chemicals and don’t produce copper waste.</li><li>If you are prototyping PCBs using novel materials on unconventional substrates, additive prototyping tools, like <a href="https://www.voltera.io/products/nova">Voltera’s NOVA materials dispensing system</a>, will better cater to your needs.</li></ul><p>Investing in an additive tool makes the most sense if you’re prototyping PCBs in-house and need rapid iterations. However, if you’re a hobbyist who only builds circuit boards occasionally, additive methods may not be the most cost-effective option.</p><h3>Subtractive methods for PCB prototypes</h3><p>In small-volume contexts, many people create PCBs in-house using subtractive techniques, where copper is selectively removed or masked.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c03943a4373b97528912db_prototype-pcbs-in-house-cnc-milling.webp" loading="lazy" alt="Close-up view of a CNC router milling a circuit pattern onto a copper-clad circuit board" width="auto" height="auto"></div><figcaption>A CNC router milling a copper-clad board to make PCBs</figcaption></figure><p>CNC milling uses a small desktop CNC router to physically mill away the unwanted copper from a copper-clad board. The ECAD design is first loaded into the CNC, which uses a very fine cutting bit to trace out the gaps between circuit traces, essentially carving out the circuit pattern from the copper layer. The result is similar to an etched board, but achieved by machining.&nbsp;</p><p><strong>Pros</strong></p><ul><li>CNC milling is quick for single boards. Once set up, you can get a finished board in under an hour, with no drying or chemical cleanup.&nbsp;</li><li>Modern PCB mills can achieve decent resolution (e.g., a trace width of <a href="https://ece.illinois.edu/about/eshop/prototyping-guidelines" target="_blank">0.3 mm</a>).</li></ul><p><strong>Cons</strong></p><ul><li>Very fine-pitch circuits or high-density boards may be challenging.</li><li>The finish of traces is not as smooth as chemical etching.</li><li>When setting up in an office or lab environment, you’ll need proper ventilation for hazardous dust.</li></ul><p>Check out our comparison blog on <a href="https://www.voltera.io/blog/cnc-milling-vs-direct-ink-writing-pcbs-stack">CNC milling vs direct-ink-writing for PCBs</a> for more information.</p><h4>Laser printer toner transfer</h4><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c039976aef8bda03517a1e_prototype-pcbs-in-house-toner-transfer.webp" loading="lazy" alt="Heart-shaped PCB pattern transferred onto a copper-clad board using the laser printer toner transfer method, prior to etching" width="auto" height="auto"></div><figcaption>A laser-printed heart-shaped circuit on toner transfer paper</figcaption></figure><p>This method uses a laser printer to create the circuit pattern. The PCB layout is printed in mirror image with toner onto a special paper substrate. This print is then placed toner-side down on the copper board and heated (using a clothes iron or laminator) to re-melt the toner, which then adheres to the copper.&nbsp;</p><p>After cooling, the paper is soaked and peeled off, leaving the black toner pattern stuck on the copper as an etch resist. The board is then etched in acid, which removes copper except under the toner traces.</p><p><strong>Pros</strong></p><ul><li>It is one of the fastest ways to construct a circuit in-house.&nbsp;</li><li>With practice, trace widths around <a href="https://hackaday.com/2016/09/12/take-your-pcbs-from-good-to-great-toner-transfer/" target="_blank">0.15 mm</a> are feasible.</li><li>It’s a low-cost technique and doesn’t require special chemicals beyond common etchant.</li></ul><p><strong>Cons</strong></p><ul><li>The process can be unreliable. Success depends on many variables such as paper type, toner brand, iron temperature, pressure, and timing.</li><li>For double-sided boards, aligning the two layers is tricky.</li></ul><h3>Photolithography</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68c039cd3292b8059c675fb2_prototype-pcbs-in-house-photo-etching.webp" loading="lazy" alt="Copper-clad PCB board with photosensitive resist pattern applied, shown next to printed transparency film, in preparation for UV photo-etching" width="auto" height="auto"></div><figcaption>A copper-clad board with photosensitive resist pattern for UV photo-etching</figcaption></figure><p>Also known as ultraviolet (UV) photo-etching, this method uses photosensitive PCB boards, a type of copper boards pre-coated with a light-sensitive resist layer. The PCB pattern is printed in black onto clear transparency film using a laser printer or photoplotter. The transparency is placed over the photosensitive board and exposed to UV light. Where the black ink blocks the UV, the underlying resist stays unexposed and will later protect copper; where transparent, the resist hardens.&nbsp;</p><p>After exposure, the circuit board is developed in a chemical developer, washing away the unexposed resist and revealing a precise copper pattern ready for etching. Etching then removes the bare copper, as usual, and finally the remaining hardened resist is stripped to leave the finished copper traces.</p><p><strong>Pros</strong></p><ul><li>Photo-etching can achieve finer traces and spacings.</li><li>It’s suitable for more complex circuits and yields repeatable results if the process is well-calibrated.</li></ul><p><strong>Cons</strong></p><ul><li>The process involves more steps and chemicals. Beginners must handle timings and development carefully — under- or over-exposure can ruin the pattern.</li><li>It has a more stringent requirement of the setup environment — a completely dark workspace for handling the unexposed boards.</li></ul><h2>Post-processing&nbsp;</h2><p>No matter how the PCB is made, whether by etching, milling, or a DIW machine, after fabrication you have a bare board that needs to be populated with components to become a working circuit. The assembly steps typically involve:</p><ul><li>Drilling (if double-sided or multilayer)</li><li>Soldering and reflowing</li><li>Testing for connections, continuity, and shorts</li><li>Final touches like mounting enclosures or coloring</li></ul><h2>Conclusion</h2><p>Making PCBs for in-house prototyping involves a mix of planning and choosing the right construction method. Breadboards offer a quick reality check for simple ideas, but for a robust and final-feel prototype, learning how to make custom PCBs, especially using additive manufacturing technologies, will be invaluable.</p><p>Interested in learning more about PCB prototyping? Check out these resources:</p><ul><li>Application: <a href="https://www.voltera.io/use-cases/applications">PCB Prototyping</a></li><li>Customer story: <a href="https://www.voltera.io/use-cases/customer-stories/itiz-revolutionizing-engineering-education-v-one">Revolutionizing PCB Design Education with V-One</a></li><li>Video: <a href="https://youtu.be/xaPmLgafT38">Printing a Decimal Counter Circuit with Silver Conductive Ink on FR1</a></li><li>Blog: <a href="https://www.voltera.io/blog/3d-printing-pcb-printing-difference">3D Printing vs. PCB Printing — What’s the Difference?</a></li></ul><p>Want to make PCB prototypes with V-One? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=prototype-pcbs-in-house&utm_content=book-a-meeting">Book a meeting</a> to speak with one of our technical representatives.</p><h2>References</h2><p>[1] Verbelen, Y., Belle, D. V., &amp; Tiete, J. (2013). Experimental Analysis of Small Scale PCB Manufacturing Techniques for Fablabs. <em>International Journal of Engineering Innovation &amp; Research</em>. 2(2), 136–143. <a href="https://www.researchgate.net/publication/268078465_Experimental_Analysis_of_Small_Scale_PCB_Manufacturing_Techniques_for_Fablabs" target="_blank">https://www.researchgate.net/publication/268078465_Experimental_Analysis_of_Small_Scale_PCB_Manufacturing_Techniques_for_Fablabs</a>.</p><p>[2] Scherz, P., &amp; Monk, S. (2016). <em>Practical Electronics for Inventors, Fourth Edition</em>. O’Reilly Online Learning. <a href="https://www.oreilly.com/library/view/practical-electronics-for/9781259587559/" target="_blank">https://www.oreilly.com/library/view/practical-electronics-for/9781259587559/</a>.</p><p>[3] Rao H. C, Varaprasad, B. K. S. V. L., &amp; Goel, S. (2021). Direct Ink Writing as an Eco-Friendly PCB Manufacturing Technique for Rapid Prototyping. 2021 Fourth International Conference on Electrical, <em>Computer and Communication Technologies (ICECCT)</em>, 1–7. <a href="https://doi.org/10.1109/icecct52121.2021.9616903" target="_blank">https://doi.org/10.1109/icecct52121.2021.9616903</a>.</p>

How to Prototype PCBs In-House

Want to make PCBs in-house? We walk you through solderless breadboards, additive, and subtractive PCB prototyping to help you make the right choice. 

How to Prototype PCBs In-House?

<p id="">Electronics encapsulation refers to the process of enclosing and protecting electronic components, circuits, or chips in a durable material or “package.” The encapsulating material (sometimes called a molding compound or potting compound) serves as a barrier against environmental factors like moisture, dust, and harsh chemicals, and shields the device from mechanical stress and vibration.</p><p id="">Over the decades, encapsulation approaches have evolved significantly. Historically, hermetic encapsulation (a method of sealing sensitive electronic components inside airtight metal or ceramic enclosures) was common, as it completely blocked moisture and gases. This was especially important in aerospace or military-grade devices [1].&nbsp;</p><p id="">Since the 1970s, the industry has shifted toward polymer-based plastic encapsulation due to its low cost, ease of processing, and high throughput. Today, encapsulating components usually involves applying polymer resins (epoxies, silicones, polyurethanes, etc.) using automated dispensing, molding, or conformal coating systems.&nbsp;</p><h2 id="">Common types of encapsulation</h2><h3 id="">Potting electronics</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39adb58aa0ea58e6775e8_electronics-encapsulation-potting-pcb-fr4-silicone.webp" loading="lazy" alt=""></div><figcaption>Schematic of an encapsulated PCB assembly, adapted from ©<a href="https://www.mdpi.com/1996-1073/16/4/2028" target="_blank">Hu C., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">In the context of electronics and semiconductors, potting and encapsulation are often used interchangeably. Potting is an encapsulation process where an entire electronic assembly or a larger section of a circuit is placed into a mold (often referred to as a “pot”) and then filled with a potting material (typically a resin) to cure into place.</p><p id="">Potting applications include:</p><ul id=""><li>Submersible or outdoor electronics <a href="https://www.grandviewresearch.com/industry-analysis/potting-compounds-market-report" id="">in harsh environments</a></li><li>High-voltage circuits (to prevent arcing) [2]</li><li><a href="https://www.masterbond.com/techtips/tamper-resistant-potting-and-encapsulation-compounds" id="">Tamper-resistant</a> designs</li></ul><h3 id="">Dam and fill</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39b64c9666a9850ee2f2f_electronics-encapsulation-dam-and-fill-chip.webp" loading="lazy" alt="Die micrograph and close-up view of a chip in a CPGA85 ceramic package, partially encapsulated using the dam-and-fill technique, showing the rectangular chamber with exposed left and right electrodes for liquid sample contact."></div><figcaption>A chip partially encapsulated using dam and fill ©<a href="https://www.mdpi.com/2306-5354/9/5/218" target="_blank">Tabrizi, H. O., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">A less common variant of potting, dam-and-fill involves first dispensing a high-viscosity “dam” around the component, then flooding the enclosed area with a lower-viscosity encapsulant. Unlike potting, which submerges the entire assembly, dam-and-fill targets only specific areas, allowing precise control over material placement while minimizing resin use. This makes it useful for precision applications or components that require partial exposure, such as optical sensors or fluid-contact electrodes, though it is less widely used than potting or glob-top methods.</p><h3 id="">Direct encapsulation</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39b9f874411c7610c6d20_electronics-encapsulation-direct-glob-top-silicone.webp" loading="lazy" alt="A glob of silicone encapsulant covering interdigitated comb electrodes and electrical traces; the clear, dome-shaped material protects the components while leaving three connected wires extending from the encapsulated area."></div><figcaption>A glob of silicone encapsulant dispensed on interdigitated combs, adapted from ©<a href="https://iopscience.iop.org/article/10.1088/1741-2552/abf0d6" target="_blank">Lamont, C., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Direct encapsulation refers to dispensing an encapsulation material directly over a semiconductor die or electronic component mounted on a substrate (e.g., a PCB) and then curing it in place. It is a direct method because the encapsulant is applied only to the needed area on the board, without needing a dam or a pot.</p><p id="">Once cured, the dispensed material forms a hardened “glob” that covers the device and its wire bonds. As such, direct encapsulation is also called glob-top encapsulation. It is widely used in:</p><ul id=""><li>High-density PCBs</li><li>Miniaturized packages where space and weight are constraints</li></ul><h2 id="">Common encapsulation materials</h2><p id="">Modern electronic devices use a range of encapsulation materials, from rigid thermoset resins to flexible elastomers, chosen based on the application requirements.</p><h3>Epoxy</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39be6bd992131277e8101_electronics-encapsulation-materials-pdms-epoxy-pcb.webp" loading="lazy" alt="Small PCB assemblies encapsulated with various materials, including black PDMS, clear and epoxy, and epoxy with hermetic feedthroughs; some samples also show a surface coating of P3HT for enhanced biocompatibility."></div><figcaption>PCBs encapsulated with different materials (PDMS, epoxy and epoxy with hermetic feedthroughs and optional P3HT coating) ©<a href="https://www.nature.com/articles/s41598-023-28699-6" target="_blank">Novak, M, et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Epoxy resins are rigid thermosetting polymers often filled with silica to improve thermal conductivity and mechanical properties. They are the most widely used encapsulants in both semiconductor packaging and industrial electronics due to their strong adhesion, mechanical strength, and chemical resistance.</p><h4 id="">Pros</h4><ul id=""><li>Epoxy encapsulants form a hard, rigid shell with excellent adhesion, mechanical strength, and chemical resistance.</li><li>They are electrically insulating and can be formulated for flame retardance and high temperature resistance.</li><li>Cured epoxies are moisture resistant and have low water permeability, which allows them to protect electronics in humid conditions [3].</li></ul><h4 id="">Cons</h4><ul id=""><li>The rigidity of epoxy can be a drawback in critical applications with extreme temperature swings or mismatched thermal expansion. Repeated heating and cooling may lead to delamination or cracks in the encapsulation or at the interface [3].</li></ul><h3 id="">Silicone</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39c41748c05944dc17912_electronics-encapsulation-materials-silicone-pdms-sensor.webp" loading="lazy" alt="A diagram showing the design and performance of a battery-free, wireless pressure and temperature sensing platform. Panel (a) shows an exploded-view of the multilayer temperature and pressure sensors, with an encapsulation layer made of PDMS on top. Panel (b) presents a photograph of the unencapsulated device. Panel (c) displays the encapsulated device undergoing mechanical stretching. Panel (d) shows finite element analysis results indicating a strain distribution of up to 8.5% in the serpentine interconnects during deformation."></div><figcaption>A pressure and temperature sensor encapsulated with PDMS ©<a href="https://advanced.onlinelibrary.wiley.com/doi/full/10.1002/advs.202202980" target="_blank">Sang M., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Silicones, particularly polydimethylsiloxane (PDMS), are flexible elastomers used when mechanical flexibility or biocompatibility is needed. Common in medical electronics and wearable devices, they can be applied as soft coatings, gels, or flexible encapsulants.</p><h4 id="">Pros</h4><ul id=""><li>Silicone encapsulants are soft and elastic after curing and reduce stress on sensitive components. In one study [3], a silicone encapsulant successfully protected chronically implanted PCBs, maintaining encapsulant integrity and adhesion during 30-day accelerated aging in saline.</li><li>Silicones have excellent thermal stability and remain functional from roughly <a href="https://www.emobility-engineering.com/potting-encapsulation-ev-electronics/" id="">-40 °C up to 175 °C</a> or more, a range over which they maintain consistent properties.</li></ul><h4 id="">Cons</h4><ul id=""><li>Silicone encapsulation is not hermetic – moisture can slowly diffuse through, which can be problematic in very moisture-sensitive devices [4]</li><li>Silicone doesn’t adhere as strongly to many substrates compared to epoxy, and its low surface energy makes it easy for it to “<a href="https://www.emobility-engineering.com/potting-encapsulation-ev-electronics/" id="">wet out</a>” and flow into crevices, which can lead to poor adhesion if not primed.</li></ul><h3 id="">Polyurethane</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a39c67a32aae41bef059ae_electronics-encapsulation-materials-polyurethane-encapsulated-sensor.webp" loading="lazy" alt="A diagram illustrating a bioresorbable, stretchable wireless nerve sensor. Panel (a) shows an exploded-view of the multilayer sensor with an encapsulation layer made of bioresorbable dynamic covalent polyurethane (b-DCPU). Panel (b) shows an optical image of the fully assembled device highlighting the coiled receiver antenna and stimulation cuff. Panel (c) and (d) shows photographs of the mechanical robustness of the device under 30% stretching and 360° twisting, enabled by the soft encapsulation and serpentine electrode design"></div><figcaption>Neural-stimulating electrodes with a bioresorbable dynamic covalent polyurethane (b-DCPU) encapsulation layer ©<a href="https://www.nature.com/articles/s41467-020-19660-6" target="_blank">Choi, Y.S., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Polyurethanes (PU) are polymers formed by reacting diisocyanates with polyols, resulting in urethane linkages [5]. They strike a balance between the hardness of epoxies and the softness of silicones, offering moderate flexibility and toughness, and are useful in soft robotics, wearables, and implantables.</p><h4 id="">Pros</h4><ul id=""><li>Polyurethanes are semi-flexible (softer than epoxies but stiffer than silicone) and offer good electrical insulation and vibration damping. They tend to cure to a less rigid state, putting less stress on delicate parts [5].&nbsp;</li><li>PU potting compounds also exhibit good adhesion [5].</li></ul><h4 id="">Cons</h4><ul id=""><li>PU generally cannot withstand high <a href="https://gallaghercorp.com/polyurethane-temperature-range/" id="">temperatures</a> as well as epoxies and silicones.&nbsp;</li><li>PU is generally <a href="https://www.emobility-engineering.com/potting-encapsulation-ev-electronics/" id="">not as impermeable</a> to water as epoxies. In a humid environment, a PU encapsulate is more likely to allow moisture ingress.</li></ul><h2 id="">Conclusion</h2><p id="">Encapsulation is a fundamental part of the electronics manufacturing process, providing protection against harsh environmental conditions like moisture, chemicals, and mechanical stress. The choice of encapsulant directly affects device reliability, making it a key design consideration for both conventional and advanced electronic systems.</p><p id="">Interested in learning more about electronics encapsulation? Check out these resources:</p><ul id=""><li>White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="">Printing a Flexible PCB with Silver Ink on PET</a></li><li>Application: <a href="https://www.voltera.io/use-cases/applications/adhesive-dispensing" id="">Adhesive Dispensing Systems</a></li><li>Blog: <a href="https://www.voltera.io/blog/thermal-interface-material-tim">What Is Thermal Interface Material (TIM)?</a></li></ul><p id="">Want to explore dispensing encapsulants with <a href="http://voltera.io/products/nova" id="">NOVA</a>? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=electronics-encapsulation&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">References</h2><p id="">[1] Inamdar, A., Driel, V., &amp; Zhang, G. (2025). Electronics packaging materials and component-level degradation monitoring. <em id="">Frontiers in Electronics</em>, 6. <a href="https://doi.org/10.3389/felec.2025.1506112" id="">https://doi.org/10.3389/felec.2025.1506112</a>.</p><p id="">[2] Du, S. Baek. Y., Wang, G., &amp; Bhattacharya, S. (2010, November 1). Design considerations of high voltage and high frequency transformer for solid state transformer application. <em id="">IEEE Xplore</em>. <a href="https://doi.org/10.1109/IECON.2010.5674991" id="">https://doi.org/10.1109/IECON.2010.5674991</a>.&nbsp;</p><p id="">[3] Adam, C., M Münch, P Kleinschnittger, Barth, T., &amp; Krautschneider, W. H. (2024). Rapid prototyping of molds for the encapsulation of electronic implants using additive manufacturing. <em id="">Additive Manufacturing Meets Medicine (AMMM)</em>. <a href="https://doi.org/10.18416/AMMM.2024.24091858" id="">https://doi.org/10.18416/AMMM.2024.24091858</a>.</p><p id="">[4] Lamont, C., Grego, T., K. Nanbakhsh, A. Shah Idil, Giagka, V., A. Vanhoestenberghe, Cogan, S., &amp; Donaldson, N. (2021). Silicone encapsulation of thin-film SiO x , SiO x N y and SiC for modern electronic medical implants: a comparative long-term ageing study. <em id="">Journal of Neural Engineering</em>, 18(5), 055003–055003. <a href="https://doi.org/10.1088/1741-2552/abf0d6" id="">https://doi.org/10.1088/1741-2552/abf0d6</a>.&nbsp;</p><p>[5] Bonomo, M., Taheri, B., Bonandini, L., Castro-Hermosa, S., Brown, T. M., Zanetti, M., Menozzi, A., Barolo, C., &amp; Brunetti, F. (2020). Thermosetting Polyurethane Resins as Low-Cost, Easily Scalable, and Effective Oxygen and Moisture Barriers for Perovskite Solar Cells.<em id=""> ACS Applied Materials &amp; Interfaces</em>, 12(49), 54862–54875. <a href="https://doi.org/10.1021/acsami.0c17652" id="">https://doi.org/10.1021/acsami.0c17652</a>.</p>

What Is Electronics Encapsulation?

Discover encapsulation methods like potting and glob top, and materials such as epoxy, silicone, and polyurethane, including their pros and cons.

<p id="">Mention droplet dispensing and you may immediately think of lab-on-a-chip (LoC) devices. Indeed, LoC devices rely on droplet dispensing systems or pipettes to distribute liquids for disease diagnostics. However, the application of droplet dispensing extends beyond life sciences. It finds various applications in consumer electronics (home inkjet printers), optics (lens arrays for fiber optics), life sciences (LoC systems, medical inhalers) as well as electronics manufacturing (dispensing solder droplets for flip chip bonding — attaching semiconductor chips to a substrate by flipping them onto tiny solder bumps) [1].&nbsp;</p><h2 id="">How does droplet dispensing work?</h2><p id="">Dispensing droplets manually involves using a syringe or micropipette to release individual droplets, and is common in laboratories for liquid handling. Micropipettes are engineered to deliver highly reproducible volumes and can reduce human variability, but achieving this precision requires proper technique and therefore subject to inter‑individual imprecision [2].</p><p>Automated droplet dispensing systems, in contrast, offer superior reliability by accurately jetting (drop-on-demand <a href="https://www.voltera.io/blog/what-is-printed-electronics-inkjet" id="">jetting systems</a>) or extruding (<a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> systems) single discrete volumes of materials from a nozzle to a precise location. The target volume of each drop can range widely, from picoliters in microelectronics to microliters in lab applications. Achieving consistent volume is crucial in droplet dispensing for accuracy and reproducibility [3].</p><h2 id="">Droplet dispensing applications</h2><h3 id="">Electronics manufacturing</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a4917c15908405944de197_droplet-dispensing-molten-metal-solder-deposition.webp" loading="lazy" alt=""></div><figcaption>Molten lead-free solder droplets dispensed with 100 µm spacing ©<a href="https://www.mdpi.com/1996-1944/10/1/1" target="_blank">Wang, C.-H. et al.</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Droplet dispensing plays a critical role in electronic packaging. For example, advanced micro droplet dispensers use piezoelectric or magnetostrictive actuation to jet precise adhesive or encapsulant droplets [4]. This has significantly improved the consistency and placement of the smaller droplets, increasing assembly speed and supporting higher-density, miniaturized devices [5].</p><p id="">Another key application in electronics manufacturing is solder droplet printing for circuit assembly. One demonstrated system [6] uses a heated pneumatic printhead to directly jet molten solder droplets onto PCB pads, where they solidify to form electrical interconnects. Such droplet-based metallization methods (including solder jetting and nanoparticle ink printing) avoid the steps of reflow ovens or wire bonding, potentially streamlining electronics assembly [6].</p><h3 id="">Optics</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a491dfbc428ee29ae5e3f2_droplet-dispensing-oled-fluorescent-pedot-pss.webp" loading="lazy" alt=""></div><figcaption>Printed thermally activated delayed fluorescence droplets in 4 × 4 mm2 square patterns with 200 DPI, adapted from ©<a href="https://www.nature.com/articles/s41467-023-43014-7#Sec13" target="_blank">Kant, C., et al</a><a href="https://www.mdpi.com/1996-1944/10/1/1" id="">.</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">In the optics and display industry, droplet dispensing technologies are used to fabricate fine optical structures and deposit light-emitting materials with great control. Inkjet printing of display layers has emerged as a promising alternative to vapor deposition in OLED and quantum-dot displays. Solutions of organic light-emitting or quantum dot materials are dispensed as microliter droplets into millions of pixel wells, then cured to form uniform thin films [7].</p><p id="">Another optical application is making microlens arrays (MLAs), used to enhance light extraction or sensing in miniaturized cameras, 3D displays, and sensors. By jetting or printing UV-curable polymer droplets to form a smooth micro-lens, droplet dispensing bypasses molding steps and allows high fill-factors over large areas, enabling rapid prototyping of optics on flat or flexible substrates [8].</p><h3 id="">In-vitro diagnostics (IVD)</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a4920ad5292297c05d6172_droplet-dispensing-ivd-chip-reagent-microwell.webp" loading="lazy" alt="Magnified view of microfluidic chip showing both wide (1.3 mm) and narrow (0.6 mm) microchannels connected to microwells containing reagent droplets."></div><figcaption>The construction of an immunodiagnostic chip supporting the movement of reagent droplets, adapted from ©<a href="https://www.nature.com/articles/s41378-022-00475-y#Sec2" target="_blank">Hu, X., el al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">In lab-on-a-chip assembly and operation, droplet-based systems precisely manipulate microliter and nanoliter droplets of fluids for assays. For example, a recent platform [9] demonstrated fully automated immunoassays by using magnetic beads to shuttle droplets between processing steps, running multiple tests in parallel on a disposable chip, and achieved sensitivities comparable to conventional lab methods.&nbsp;</p><p id="">Unlike continuous-flow microchannels, droplet-based approaches in point-of-care testing minimize sample volume, cut assay time, and allow in situ integration of functions (mixing, incubation, detection) that would otherwise require bulky instruments. They also provide a controlled, contamination-limited environment for biochemical reactions [10].</p><h3 id="">Bioprinting</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68a492308f2df32c08b31e5e_droplet-dispensing-bioprinting-bioink-cell-deposition.webp" loading="lazy" alt=""></div><figcaption>Bioprinting process ©<a href="https://link.springer.com/article/10.1007/s42242-024-00285-3" target="_blank">Ng, W. L., &amp; Shkolnikov, V</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p id="">Beyond diagnostics, droplet dispensing has a broad spectrum of expansive applications in the life sciences. In bioprinting, for example, droplet dispensing systems deposit bioink droplets containing living cells, growth factors, or other biomaterials to fabricate tissues and organoids (lab-grown miniature organs/tissues), achieving precise placement of cells at high speed [11]. This precise spatial control supports the recreation of cellular microenvironments, which is essential for studying cell-to-cell interactions, disease progression, and tissue regeneration [11].</p><h2 id="">Key considerations of droplet dispensing</h2><p id="">As seen in the applications above, a wide variety of materials can be dispensed as droplets, from metals and functional nanomaterials to polymers and bioinks. However, dispensing materials at micro to nanoliter scales comes with several important considerations.</p><ul id=""><li>Clogging: Dried residue from volatile solvents or particulate matter in the fluid can block nozzles. In addition to frequent cleaning, it may be necessary to adjust material viscosity using additives or by changing the temperature.</li><li>Inconsistency in placement and volume: Droplet volume can drift due to changes in printing parameters (e.g., drawback force) [12]. Air currents, static charge on the substrate, or inconsistent drop velocities can also affect placement. Choosing a high-precision droplet dispenser and implementing environmental controls, such as using an enclosure, are critical for consistent results.</li></ul><p id="">To learn more about dispensing best practices, check out <a href="https://www.voltera.io/blog/dispense-adhesives" id="">How to Dispense Adhesives</a>.</p><h2 id="">Conclusion</h2><p id="">Droplet dispensing is increasingly important in electronics manufacturing and the life sciences, enabling precise miniaturization. Recent work [13] suggests that adaptive intelligent control will be key to maintaining consistent droplet formation and ejection characteristics, and future advances may allow dispensers to self-tune to different liquids for optimal performance.</p><p id="">Ready to learn more about materials dispensing? Explore these resources:</p><ul id=""><li>Blog: <a href="https://www.voltera.io/blog/dot-dispensing" id="">What Is Dot Dispensing?</a></li><li>Blog: <a href="https://www.voltera.io/blog/precision-fluid-dispensing-systems" id="">What Are Precision Fluid Dispensing Systems?</a></li><li>Application overview: <a href="https://www.voltera.io/use-cases/applications/solder-paste-printing" id="">Solder Paste Printing</a></li></ul><p id="">Looking for proof-of-concept of your droplet dispensing applications? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=droplet-dispensing&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">References</h2><p id="">[1] Lindemann, T., &amp; Zengerle, R. (2008). Droplet Dispensing. <em id="">Encyclopedia of Microfluidics and Nanofluidics</em>, 402–411. <a href="https://doi.org/10.1007/978-0-387-48998-8_361" id="">https://doi.org/10.1007/978-0-387-48998-8_361</a>.&nbsp;</p><p id="">[2] Lippi, G., Lima-Oliveira, G., Brocco, G., Bassi, A., &amp; Salvagno, G. L. (2017). Estimating the intra- and inter-individual imprecision of manual pipetting. <em id="">Clinical Chemistry and Laboratory Medicine (CCLM)</em>, 55(7). <a href="https://doi.org/10.1515/cclm-2016-0810" id="">https://doi.org/10.1515/cclm-2016-0810</a>.&nbsp;</p><p id="">[3] Nikapitiya, N. Y. J. B., Nahar, M. M., &amp; Moon, H. (2017). Accurate, consistent, and fast droplet splitting and dispensing in electrowetting on dielectric digital microfluidics. <em id="">Micro and Nano Systems Letters</em>, 5(1). <a href="https://doi.org/10.1186/s40486-017-0058-6" id="">https://doi.org/10.1186/s40486-017-0058-6</a>.&nbsp;</p><p id="">[4] Zhou, C., Li, J. H., Duan, J. A., &amp; Deng, G. L. (2015). The principle and physical models of novel jetting dispenser with giant magnetostrictive and a magnifier. <em id="">Scientific Reports</em>, 5(1). <a href="https://doi.org/10.1038/srep18294" id="">https://doi.org/10.1038/srep18294</a>.&nbsp;</p><p id="">[5] Nature Research Intelligence. (n.d.). <em id="">Fluid Dispensing and Microelectronics Packaging</em>. <a href="https://www.nature.com/research-intelligence/nri-topic-summaries/fluid-dispensing-and-microelectronics-packaging-micro-82301" id="">https://www.nature.com/research-intelligence/nri-topic-summaries/fluid-dispensing-and-microelectronics-packaging-micro-82301</a>.&nbsp;</p><p id="">[6] Shu, Z., Fechtig, M., Florian Lombeck, Breitwieser, M., Zengerle, R., &amp; Koltay, P. (2020). Direct Drop-on-Demand Printing of Molten Solder Bumps on ENIG Finishing at Ambient Conditions Through StarJet Technology. <em id="">IEEE Access</em>, 8, 210225–210233. <a href="https://doi.org/10.1109/access.2020.3040035" id="">https://doi.org/10.1109/access.2020.3040035</a>.&nbsp;</p><p id="">[7] Xiong, J., Chen, J., Li, Y., Yue, X., Fu, Y., &amp; Yin, Z. (2025). Large-area OLED substrate printing path planning method based on multi-head GAT imitation learning to solve partitioned integer programming. <em id="">Scientific Reports</em>, 15(1). <a href="https://doi.org/10.1038/s41598-025-08355-x" id="">https://doi.org/10.1038/s41598-025-08355-x</a>.</p><p id="">[8] Zhong, L., Liu, W., Gong, H., Li, Y., Zhao, X., Kong, D., Du, Q., Xu, B., Zhang, X., &amp; Liu, Y. J. (2025). Electrohydrodynamically Printed Microlens Arrays with the High Filling Factor Near 90%. <em id="">Photonics</em>, 12(5), 446–446. <a href="https://doi.org/10.3390/photonics12050446" id="">https://doi.org/10.3390/photonics12050446</a>.&nbsp;</p><p id="">[9] Hu, X., Gao, X., Chen, S., Guo, J., &amp; Zhang, Y. (2023). DropLab: an automated magnetic digital microfluidic platform for sample-to-answer point-of-care testing—development and application to quantitative immunodiagnostics. <em id="">Microsystems &amp; Nanoengineering</em>, 9(1), 1–12. <a href="https://doi.org/10.1038/s41378-022-00475-y" id="">https://doi.org/10.1038/s41378-022-00475-y</a>.&nbsp;</p><p id="">[10] Trinh, T. N. D., Do, H. D. K., Nam, N. N., Dan, T. T., Trinh, K. T. L., &amp; Lee, N. Y. (2023). Droplet-Based Microfluidics: Applications in Pharmaceuticals. <em id="">Pharmaceuticals</em>, 16(7), 937. <a href="https://doi.org/10.3390/ph16070937" id="">https://doi.org/10.3390/ph16070937</a>.</p><p id="">[11] Ng, W. L., &amp; Shkolnikov, V. (2024). Jetting-based bioprinting: process, dispense physics, and applications. <em id="">Bio-Design and Manufacturing</em>, 7(5), 771–799. <a href="https://doi.org/10.1007/s42242-024-00285-3" id="">https://doi.org/10.1007/s42242-024-00285-3</a>.</p><p id="">[12] Wang, W., Chen, J., &amp; Zhou, J. (2016). An electrode design for droplet dispensing with accurate volume in electro-wetting-based microfluidics. <em id="">Applied Physics Letters</em>, 108(24). <a href="https://doi.org/10.1063/1.4954195" id="">https://doi.org/10.1063/1.4954195</a>.&nbsp;</p><p id="">[13] Jiang, J., Chen, X., Mei, Z., Chen, H., Chen, J., Wang, X., Li, S., Zhang, R., Zheng, G., &amp; Li, W. (2024). Review of Droplet Printing Technologies for Flexible Electronic Devices: Materials, Control, and Applications. <em id="">Micromachines</em>, 15(3), 333. <a href="https://doi.org/10.3390/mi15030333" id="">https://doi.org/10.3390/mi15030333</a>.</p>

What Is Droplet Dispensing?

Droplet dispensing is used in more than just life sciences. Learn about droplet dispensing applications in electronics manufacturing, optics, and beyond.

<p id=""><a href="https://www.copprint.com/" target="_blank" id="">Copprint</a> is an advanced materials company revolutionizing printed electronics with breakthrough conductive copper nanoparticle inks. Founded in 2016, Copprint’s mission is to enable low-cost, high-performance, and sustainable additive manufacturing of conductive components. Copprint’s inks are designed for in-house circuit board manufacturing by replacing chemical etching processes with additive processes.</p><p id="">We recently sat down with Ofer Shochet, co-founder and CEO of Copprint, to talk about prototyping with nano copper inks. Read on to learn what he had to say…</p><h2 id="">Characteristics of copper nanoparticle ink</h2><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6855a7b9feb84e21d07d1d14_copper-conductive-nanoparticle-ink-characteristics.jpg" loading="lazy" alt="Copprint’s nano copper ink in a cartridge" width="auto" height="auto" id=""></div></figure><p id=""><strong id="">Q: What makes copper nanoparticle ink unique from other conductive inks?</strong></p><p id="">Copper ink stands out from other conductive inks due to its:</p><ul id=""><li id="">Cost-effectiveness: Copper is significantly cheaper than silver and can reduce costs by 5 to 10 times.</li><li id="">High-conductivity: When properly sintered, copper offers excellent electrical performance.</li><li id="">Sustainability: Copper has the lowest CO₂e per performance relative to any silver or carbon conductive ink. The carbon footprint of conductive copper inks is 40 times less than silver. Copper’s carbon footprint is also slightly lower than carbon’s, and it delivers the same electrical performance using 100 to 1,000 times less material.</li><li id="">Abundance: Copper is much more abundant and affordable than silver, ensuring a stable and scalable supply, as well as lower costs and reduced cost volatility.</li><li id="">Recyclability: Copper inks can be composted and recycled.</li></ul><h2 id="">Benefits of Copprint ink for rapid prototyping</h2><p id=""><strong>Q: What are the benefits of using Copprint ink for rapid electronics prototyping?</strong></p><p id="">Copprint copper nano inks are designed for speed, precision, and flexibility, making them ideal for rapid prototyping. Their print-ready formulations work with standard printing techniques, allowing engineers to quickly iterate designs without specialized equipment. The conductive inks are sintered in seconds at 150-300°C, depending on the substrate, enabling fast turnaround times and low-cost development for functional prototypes.&nbsp;</p><p id="">Additionally, the inks support fine geometries and high-resolution patterns, making them suitable for complex circuits in applications like <a href="https://www.voltera.io/use-cases/applications/wearable-flexible-electronics" id="">wearables</a>, IoT devices, and smart packaging. Since copper nano ink can be used for both prototyping and large-scale manufacturing, using it during the prototyping phases facilitates a smoother transition to mass production.</p><h2 id="">Nano copper ink sustainability benefits</h2><p id=""><strong id="">Q: What sustainability benefits does nano copper ink offer?</strong></p><p id="">Additive manufacturing with copper conductive inks offers a sustainable alternative to the highly polluting chemical etching processes used in traditional circuit board production. By using nano copper inks in a design-for-additive-manufacturing (DfAM) approach, engineers can print copper only where it’s needed, eliminating the wasteful etching of copper-clad laminates. This method not only reduces material usage and cost but also enables ultra-thin copper layers, lighter boards, and integrated functionality.&nbsp;</p><p id="">Copper inks are also highly recyclable and serve as a more affordable and abundant substitute for expensive and scarce silver used in silver-based inks. Copprint’s additive process further enhances sustainability by cutting CO₂ emissions by over 50% and minimizing the use of water, energy, and toxic chemicals. This approach supports cleaner production and contributes to a smaller environmental footprint and is already being explored in <a href="https://www.voltera.io/blog/flexible-hybrid-electronics" id="">flexible electronics</a>, smart fabrics, and embedded IoT systems.</p><h2 id="">Rheological requirements for DIW and screen printing</h2><p id=""><strong id="">Q: How do your ink formulations address the rheological requirements for compatibility with direct ink writing and screen printing?</strong></p><p id="">Copprint’s inks are engineered with precise rheological control to ensure compatibility with a wide range of <a href="https://www.voltera.io/blog/screen-printing-direct-ink-writing-printed-electronics" id="">additive PCB manufacturing methods</a>. The formulations maintain optimal <a href="https://www.voltera.io/blog/what-is-viscosity" id="">viscosity</a>, <a href="https://www.voltera.io/blog/what-surface-energy" id="">surface tension</a>, and particle dispersion, allowing for smooth flow, accurate deposition, and excellent adhesion. The inks deliver high-resolution patterns with minimal spreading or clogging across both rigid and flexible substrates, supporting scalable production and prototyping.&nbsp;</p><p id="">The product portfolio of inks is designed for specific substrates, and the viscosity, thixotropy, and particle size distribution (PSD) are tailored to fit different printing techniques and outcomes such as thin or thick printing.</p><p id="">The entire product portfolio is compatible with the <a href="https://www.voltera.io/products/nova" id="">NOVA</a> materials dispensing system.</p><h2 id="">Copprint ink in innovative prototyping</h2><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6855a70064dabc492dd780fb_conductive-nano-copper-ink-rfid-antenna.jpg" loading="lazy" alt="__wf_reserved_inherit" width="auto" height="auto" id=""></div></figure><p id=""><strong id="">Q: Can you share an interesting or innovative project that has used Copprint ink in a prototyping context?</strong></p><p id="">An example is the process towards large-scale manufacturing of radio-frequency identification <a href="https://www.voltera.io/blog/copper-rfid-tag" id="">(RFID) antennas</a>. The prototyping phase requires many cycles for optimal radio frequency (RF) design and many different circuits and tests. As optimization needs to be done using the same manufacturing technique, using copper inks for both prototyping and large-scale production makes this possible.</p><p id="">To learn more about Copprint and their copper nanoparticle materials, visit their <a href="https://www.copprint.com/" target="_blank" id="">website</a> or reach out to them at <a href="mailto:info@copprint.com">info@copprint.com</a>.</p><h2 id="">Additional resources</h2><ul id=""><li id="">Video: <a href="https://youtu.be/2COFihlYVos" id="">Printing Copper RFID Tags</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper" id="">Printing an RFID Tag with Copper Ink on Paper</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/role-conductive-inks-additive-electronics-manufacturing" id="">Role of Conductive Inks in Additive Electronics Manufacturing</a></li></ul>

Prototyping with Conductive Nano Copper Ink from Copprint

Learn how Copprint’s nano copper inks create a seamless transition from prototyping to large-scale manufacturing while improving sustainability goals.

<p id="">Adhesives play a crucial role in the manufacturing of modern electronics and product development, from securing tiny surface-mount components on circuit boards to bonding structural parts in advanced devices. Unlike mechanical fasteners, adhesives bond dissimilar materials with uniform stress distribution, while providing thermal and electrical insulation, simplifying structural design [1].</p><h2 id="">Types of adhesives</h2><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68486f954b72fe8b4a4a4b0f_dispense-adhesives-polyurethane-epoxy-copolymer-switchable.webp" loading="lazy" alt="A diagram showing the advancements in adhesives in chronological order. From left to right: natural adhesives (before 1900s), phenolic resin (1900s), polyurethane (1930s), epoxy resin (1950s), ethylene-vinyl acetate copolymer (1960s), and switchable adhesives (2000s)" width="auto" height="auto" id=""></div><figcaption id="">Chronology of advancements in adhesives ©<a href="https://advanced.onlinelibrary.wiley.com/doi/full/10.1002/advs.202200264" target="_blank" id="">Liu, Z., &amp; Yan, F.</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><p id="">Adhesives evolved from ancient natural materials like clay to early synthetics like phenolic resins. Polymer advances in the 1930s introduced epoxy resins (1950s), cyanoacrylate (1957), and hot melt glues (1960s) [2].&nbsp;</p><p id="">The most recent innovations in adhesives are concerned with greener solutions. For example:</p><ul id=""><li id="">Switchable adhesives activated by light, heat, magnetic fields, or electricity, enabling reversible bonding in robotics, electronics, and microfluidics [2][3]</li><li id="">Poly(hydroxyurethane) (PHU) derived from cyclic carbonates and amines as a safer, non-isocyanate alternative to polyurethanes, expanding anticorrosion and flame-retardant applications [4]</li><li id="">Biocompatible adhesives engineered for strong tissue adhesion plus antimicrobial activity, drug delivery, or self-healing, improving surgical outcomes [5]</li></ul><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68486fd4097c32408fb3cc0d_dispense-adhesives-high-temperature-anticorrosion-antimicrobial.webp" loading="lazy" alt="Four PHU coating applications: abrasion-resistant flooring (PHU-epoxy), flame-retardant (phosphorus-based), anticorrosion (silica-based), and antimicrobial (ammonium-bearing)." width="auto" height="auto" id=""></div><figcaption id="">Applications of hybrid poly(hydroxyurethane) (PHU) adhesives ©<a href="https://pubs.acs.org/doi/full/10.1021/acssuschemeng.1c02558" target="_blank" id="">Gomez-Lopez, A., et al</a><a href="https://www.astrj.com/A-Lean-Robotics-Approach-to-the-Scheduling-of-Robotic-Adhesive-Dispensing-Process,152332,0,2.html" id="">.</a>,<a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id=""> CC BY 4.0</a></figcaption></figure><h2 id="">Adhesive dispensing methods</h2><p id="">Selecting the appropriate adhesive dispensing method is as critical as the adhesive choice. The main methods include manual dispensing, non-contact jetting, and contact dispensing.</p><p id="">Manual glue dispensers, such as handheld hot melt glue guns, have been reported to have the <a href="https://www.adhesivesmag.com/articles/98601-common-dispensing-challenges-and-solutions-for-adhesives-and-other-materials" id="">lowest shot-to-shot repeatability</a> (the system’s ability to deliver consistent volumes of adhesive) of all. For precision applications, the goal is to deposit the right adhesive amount at the right location with repeatable accuracy.&nbsp;</p><p id="">Researchers [6] have identified contact dispensing systems as “the most effective dispensing technology” for accommodating a wide viscosity range. These systems vary from desktop <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> (DIW) to <a href="https://www.astrj.com/A-Lean-Robotics-Approach-to-the-Scheduling-of-Robotic-Adhesive-Dispensing-Process,152332,0,2.html" id="">4-axis robotic hands</a>.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/684870074d8b0d8060663831_dispense-adhesives-contact-robotic-hand-pcb.webp" loading="lazy" alt="A simulation of a lean robotics adhesive dispensing system on a work station dispensing adhesives on the edge of one of the components of a printed circuit board" width="auto" height="auto" id=""></div><figcaption id="">A robotic adhesive dispensing system © <a href="https://www.astrj.com/A-Lean-Robotics-Approach-to-the-Scheduling-of-Robotic-Adhesive-Dispensing-Process,152332,0,2.html" target="_blank" id="">Sobaszek, Ł.</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><h2 id="">Choosing adhesive dispensing equipment and substrates</h2><p id="">Selecting adhesive and fluid dispensing systems requires balancing cohesive forces (within the adhesive) and adhesive forces (between the adhesive and substrate).</p><h3 id="">Rheological and chemical properties of adhesives</h3><p id=""><a href="https://www.voltera.io/blog/what-is-viscosity" id="">Viscosity</a> governs flow characteristics, affects droplet or line formation, and impacts equipment compatibility. In general, low-viscosity adhesives are suited to non-contact jetting, while high-viscosity adhesives often necessitate contact dispensing systems due to their flow resistance.&nbsp;</p><p id="">For example, one study [7] found that epoxy adhesives with 60 weight percentage hybrid fillers (graphite, boron nitride, and silver flakes) exhibited an 11-fold viscosity increase over neat epoxy, directly impacting flow resistance during dispensing.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68487056d8fed2bf44a4d976_dispense-adhesives-equipment-substrate-rheology-wettability.webp" loading="lazy" alt="Diagram categorizing droplet impact outcomes into deposition, beaded deposition corona splash/break-up, prompt splash/break-up, partial rebound, and full rebound" width="auto" height="auto" id=""></div><figcaption id="">Classification of droplet impact behaviors during deposition processes ©<a href="https://www.mdpi.com/2079-6412/13/5/817#" target="_blank" id="">Krishnan, G. H., et al.</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><h3 id="">Substrate wettability</h3><p id="">The <a href="https://www.voltera.io/blog/what-surface-energy" id="">surface energy</a> of substrates dictates adhesive wetting and bond strength. High-surface-energy materials, such as metals, ceramics, and glass, enable adhesives to spread and form strong interfacial contact. Conversely, low-surface-energy polymers like polytetrafluoroethylene (PTFE), polyethylene (PE), or polypropylene inhibit wetting, causing adhesives to bead up and delaminate [8].</p><h2 id="">Adjusting dispensing parameters </h2><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/68486f4bf153640c76367dd5_dispense-adhesives-adjusting-parameters-pressure-time.webp" loading="lazy" alt="Two valves mounted on commercial syringes. Upper valve: long nozzle (16.5 mm) and external ring magnet fixture. Lower valve: short nozzle (5.5 mm) and ring magnet attached by clamping fixture" width="auto" height="auto" id=""></div><figcaption id="">Dispensing syringes equipped with valves ©<a href="https://www.mdpi.com/2072-666X/4/1/9" target="_blank" id="">Bammesberger, S. B., et al</a><a href="https://www.astrj.com/A-Lean-Robotics-Approach-to-the-Scheduling-of-Robotic-Adhesive-Dispensing-Process,152332,0,2.html" id="">.</a>, <a href="http://creativecommons.org/licenses/by/3.0/" target="_blank" id="">CC BY 3.0</a></figcaption></figure><p id="">Fine-tuning an adhesive dispensing system’s parameters is essential to ensure high-quality adhesive application, as small adjustments significantly affect feature formation, size, and bond strength. Key parameters include dispensing pressure, time, rate, lifting speed, needle size, and temperature.</p><h3 id="">Dispensing pressure</h3><p id="">Dispensing pressure directly influences adhesive flow and feature consistency. High-viscosity adhesives need greater pressure to flow through the needle; however, too much pressure can cause overflow or tailing, leading to more waste and inconsistent deposit shapes [6].</p><h3 id="">Dispensing time and rate</h3><p id="">Dispensing time (the duration for which the adhesive is actively extruded) and dispensing rate (volume dispensed per unit time) determine deposit size and shape. Longer dispensing times increase deposit size and wetting area, but excessive durations produce unstable droplets due to persistent liquid bridges [6].</p><h3 id="">Lifting speed&nbsp;</h3><p id="">The speed at which the dispensing tip lifts away from the substrate also affects deposit morphology. Lower lifting speeds allow the adhesive more time to stabilize, forming smoother and more uniform features. In contrast, higher lifting speeds can produce uneven feature shapes with pronounced tailing and instability [6].</p><h3 id="">Temperature control</h3><p id="">Adjusting the temperature of the adhesive can alter its viscosity and improve dispensability. For <a href="https://bonstone.com/affect-of-temperature-on-the-cure-properties-of-two-part-adhesives/" target="_blank" id="">two-part adhesives</a> and structural acrylics which have a limited pot life, dynamic temperature control helps ensure consistent application even as ambient conditions fluctuate.&nbsp;</p><p id="">Slightly increasing the temperature may reduce viscosity, facilitating smoother adhesive flow through the syringe barrels and needle. However, excessive temperatures could prematurely initiate curing or degrade adhesive performance [8].</p><h2 id="">Conclusion</h2><p id="">Dispensing adhesives is a precise science — it requires understanding the chemistry and behavior of your chosen adhesives as well as mastering the equipment and process control parameters. By selecting the right type of adhesive for the job and using appropriate adhesive dispensing systems, researchers, engineers, and product designers can optimize their designs and increase efficiency and throughput.</p><p id="">Interested in learning more about dispensing adhesives? Check out these resources:</p><ul id=""><li id="">Application overview: <a href="https://www.voltera.io/use-cases/applications/adhesive-dispensing" id="">Adhesive dispensing systems</a>&nbsp;</li><li id="">Blog: <a href="https://www.voltera.io/blog/electronics-encapsulation" id="">What Is Electronics Encapsulation?</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/dot-dispensing" id="">What Is Dot Dispensing?</a></li></ul><p id="">Want to explore dispensing adhesives with <a href="http://voltera.io/products/nova" id="">NOVA</a>? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=dispense-adhesives&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">Frequently Asked Questions</h2><h3 id="">What are the best adhesive systems for automated dispensing?</h3><p id="">The best options for automatic adhesive dispensing combine precise flow control with easy calibration. <a href="http://voltera.io/products/nova" id="">NOVA</a> uses <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> (DIW) to handle a wide range of materials, from epoxies to flexible conductive inks, while maintaining consistent bead geometry and minimal waste.</p><h3 id="">What maintenance does adhesive dispensing equipment require?</h3><p id="">Regular cleaning and inspection reduce downtime. We recommend keeping nozzles clear and storing materials properly to ensure smooth, efficient operation with little maintenance needed for ongoing reliability and productivity.</p><h3 id="">Where can I find help if I’m new to dispensing systems?</h3><p id=""><a href="https://www.voltera.io/about/contact-us" id="">Reach out</a> for technical support to review parameters, troubleshoot issues, or choose materials. Our expert advice helps you operate your system more efficiently and avoid wasted runs.</p><h3 id="">Can I use the same dispensing setup for solder pastes?</h3><p id="">No. Solder pastes behave differently — they contain metal particles that melt during the reflow process. The dispensing principles are similar, but cure temperatures, handling, and cleanup differ. Always follow the correct process to protect your machine and maintain productivity.</p><h3 id="">Do adhesives also act as sealants?</h3><p id="">Many formulations double as sealants for environmental sealing, gasketing, or protection around sensitive parts. Selecting the right chemistry prevents leaks and ensures long-term reliability.</p><h2 id="">References</h2><p id="">[1] Maggiore, S., Banea, M. D., Stagnaro, P., &amp; Luciano, G. (2021). A Review of Structural Adhesive Joints in Hybrid Joining Processes. <em id="">Polymers</em>, 13(22), 3961. <a href="https://doi.org/10.3390/polym13223961" target="_blank" id="">https://doi.org/10.3390/polym13223961</a>.&nbsp;</p><p id="">[2] Liu, Z., &amp; Yan, F. (2022). Switchable Adhesion: On‐Demand Bonding and Debonding. <em id="">Advanced Science</em>, 9(12), 2200264. <a href="https://doi.org/10.1002/advs.202200264" target="_blank" id="">https://doi.org/10.1002/advs.202200264</a>.</p><p id="">[3] Wasay, A., &amp; Sameoto, D. (2014). “Geckofluidics”: A new concept in reversible bonding of Microfluidic Channels. <em id="">Hilton Head Workshop 2014: A Solid-State Sensors, Actuators and Microsystems Workshop</em>. <a href="https://doi.org/10.31438/trf.hh2014.119" target="_blank" id="">https://doi.org/10.31438/trf.hh2014.119</a>.&nbsp;</p><p id="">[4] Gomez-Lopez, A., Panchireddy, S., Grignard, B., Calvo, I., Jerome, C., Detrembleur, C., &amp; Sardon, H. (2021). Poly(hydroxyurethane) Adhesives and Coatings: State-of-the-Art and Future Directions. <em id="">ACS Sustainable Chemistry &amp; Engineering</em>, 9(29), 9541–9562. <a href="https://doi.org/10.1021/acssuschemeng.1c02558" target="_blank" id="">https://doi.org/10.1021/acssuschemeng.1c02558</a>.&nbsp;</p><p id="">[5] Pinnaratip, R., Bhuiyan, M. S. A., Meyers, K., Rajachar, R. M., &amp; Lee, B. P. (2019). Multifunctional Biomedical Adhesives.<em id=""> Advanced Healthcare Materials</em>, 8(11), 1801568. <a href="https://doi.org/10.1002/adhm.201801568" target="_blank" id="">https://doi.org/10.1002/adhm.201801568</a>.&nbsp;</p><p id="">[6] Zou, J., Huang, M., Zhao, D., Chen, F., &amp; Wang, D. (2023). Modeling the contact dispensing process of conductive adhesives with different viscosities and optimization of droplet deposition. <em id="">Frontiers in Materials</em>, 10. <a href="https://doi.org/10.3389/fmats.2023.1183747" target="_blank" id="">https://doi.org/10.3389/fmats.2023.1183747</a>.&nbsp;</p><p id="">[7] Kumar, R., Mishra, A., Sahoo, S., Panda, B. P., Mohanty, S., &amp; Nayak, S. K. (2019). Epoxy‐based composite adhesives: Effect of hybrid fillers on thermal conductivity, rheology, and lap shear strength. <em id="">Polymers for Advanced Technologies</em>, 30(6), 1365–1374. <a href="https://doi.org/10.1002/pat.4569" target="_blank" id="">https://doi.org/10.1002/pat.4569</a>.&nbsp;</p><p id="">[8] Lall, P., Goyal, K., Schulze, K., &amp; Miller, S. (2021). Electrically Conductive Adhesive Interconnections on A<em id="">dditively Printed Substrates</em>. <a href="https://doi.org/10.1109/itherm51669.2021.9503235" target="_blank" id="">https://doi.org/10.1109/itherm51669.2021.9503235</a>.</p>

Adhesive Dispensing Explained: Methods and Materials

Learn about adhesive dispensing methods, material rheology and chemical properties, substrate compatibility, and dispense parameters.

<p id="">In this webinar, our Support Lead, Nathan Shinkar, was joined by <a href="https://www.linkedin.com/in/jackjherring/" id="">Jack Herring</a>, founder of <a href="https://www.jivamaterials.com/" id="">Jiva Materials</a>, to explore how <a href="https://www.jivamaterials.com/technology/" id="">Soluboard<sup id="">®</sup></a>, a biodegradable PCB substrate, offers a sustainable alternative to traditional FR4 boards. The session included insights on sustainability in PCB prototyping, an in-depth look at Soluboard, and how easily it integrates with our <a href="https://www.voltera.io/products/v-one" id="">V-One PCB printer</a>.</p><figure class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=X566QCE6IZY"><div><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/X566QCE6IZY" title="Webinar: Printing Biodegradable PCBs"></iframe></div></figure><h2 id="">Webinar highlights</h2><h3 id="">Why sustainability matters in PCB prototyping</h3><p id="">Nathan kicked off the session with a look at how additive electronics, more specifically <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> (DIW), help reduce e-waste:</p><ul id=""><li>Print only where needed — less material waste</li><li>No harsh chemicals or etching processes</li><li>No need for offshoring or bulk orders — fewer shipping emissions</li><li>Compatible with recyclable and biodegradable substrates like Soluboard®</li></ul><p id="">As a DIW PCB printer, V-One supports eco-conscious development by enabling desktop additive PCB prototyping with <a href="https://www.voltera.io/blog/conductive-inks" id="">conductive ink</a> printing, <a href="https://www.voltera.io/use-cases/applications/solder-paste-printing" id="">solder paste dispensing</a>, and reflow, all without relying on traditional subtractive manufacturing methods. For more advanced builds, the V-One also offers through-hole drilling to support double-sided circuits.</p><h3 id="">Soluboard<sup id="">®</sup>: The world’s first recyclable PCB substrate</h3><p id="">Jack Herring introduced Soluboard, a biodegradable and recyclable thermoplastic laminate made from natural fibers like jute and flax. Compared to FR4, Soluboard:</p><ul id=""><li>Has a reduced carbon footprint of over 68% (up to 73% for thin substrates)</li><li>Supports metal recovery via a non-hazardous hot-water recycling process</li><li>Fully decomposes natural fiber layers in ~75 days post-recycling</li><li>Is <a href="https://www.ul.com/services/certification" id="">UL-recognized</a> and compatible with through-hole and double-sided PCB designs</li><li>Is already used by original equipment manufacturers (OEMs) for sustainability-compliant hardware development</li></ul><p id="">Soluboard performs reliably in environmental and thermal testing, with lower thermal expansion than FR4—minimizing delamination and warping during soldering.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/686542eee2ab711cc41164e6_webinar-printing-biodegradable-pcbs-soluboard-benefits.webp" loading="lazy" alt="Close-up of a Soluboard® PCB showing copper traces and natural fiber backing, alongside key benefits: 68% lower carbon footprint, drop-in epoxy replacement, and water-based recyclability."></div><figcaption>Benefits of Soluboard®</figcaption></figure><h3 id="">Integrating Soluboard® with V-One</h3><p id="">Soluboard integrates directly into the V-One workflow:</p><ul id=""><li>Works with the V-One’s standard bake and reflow steps</li><li>Supports two-sided PCB prototyping with drilling and rivet pressing</li><li>Compatible with Voltera’s low-temp soldering process</li></ul><p>Soluboard is now available in limited quantities through the <a href="https://store.voltera.io/products/3-x-4-soluboard-substrates-6-pack" id="">Voltera Store</a>.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6865434b663b5a56c540804a_webinar-printing-biodegradable-pcbs-soluboards-voltera.webp" loading="lazy" alt="6 pieces of 3&quot; × 4&quot; light brown Soluboards® "></div><figcaption>Soluboard® sold on Voltera’s online store</figcaption></figure><h2 id="">Live Q&amp;A</h2><ul id=""><li><strong id="">Q</strong>: How long does it take for Soluboard to biodegrade?</li><li><strong id="">A</strong>: ~75 days for natural fibers, after the recycling process.</li></ul><ul id=""><li><strong id="">Q</strong>: Can it support multilayer or buried/blind vias?</li><li><strong id="">A</strong>: Multilayer support is on the roadmap (Q3-Q4 2025). Current minimum via diameter is 0.3 mm.</li></ul><ul id=""><li><strong id="">Q</strong>: Can any PCB shop use Soluboard?</li><li><strong id="">A</strong>: Yes, with coordination through OEMs or direct inquiry to Jiva Materials.</li></ul><ul id=""><li><strong id="">Q</strong>: What polymer is used in the blend?</li><li><strong id="">A</strong>: Polyvinyl alcohol (PVA), chosen for performance and minimal environmental impact. For more information, refer to their <a href="https://patentimages.storage.googleapis.com/94/62/b2/fa3ec3588a3513/WO2018234801A1.pdf" id="">patent document</a>.</li></ul><ul id=""><li><strong id="">Q</strong>: Is Soluboard compatible with immersion cooling or flexible PCBs?</li><li><strong id="">A</strong>: Soluboard is not currently designed for immersion-cooled or flex PCBs, but testing is ongoing.</li></ul><ul id=""><li><strong id="">Q</strong>: What are the dielectric properties?</li><li><strong id="">A</strong>: Dielectric constant ranges from ~3.5 to 4, depending on fiber type.</li></ul><ul id=""><li><strong id="">Q</strong>: How thin can the substrate go?</li><li><strong id="">A</strong>: Currently down to 0.3 mm, with thinner variants under development.</li></ul><h2 id="">Additional resources</h2><p id="">Want to learn more about sustainable PCB prototyping and how Voltera’s products help create greener electronics? Check out these resources:</p><ul id=""><li>Patent: <a href="https://patentimages.storage.googleapis.com/94/62/b2/fa3ec3588a3513/WO2018234801A1.pdf" id="">Jiva Materials’ patent document</a>&nbsp;</li><li>Blog: <a href="https://www.voltera.io/blog/prototyping-conductive-nano-copper-ink-copprint" id="">Prototyping with Sustainable Conductive Nano Copper Ink</a></li><li>Application: <a href="https://www.voltera.io/use-cases/applications/additive-pcb-prototyping">Additive PCB Prototyping</a></li></ul><p id="">Ready to talk about how V-One can help you make green electronics? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-biodegradable-pcbs&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p>

Webinar Recap: Printing Biodegradable PCBs

In this webinar, we explored Soluboard®, a biodegradable PCB substrate, and how it is compatible with Voltera’s V-One PCB printer for sustainable prototyping.

<p>Excessive heat in electronics is a leading cause of premature component failure. As modern electronic devices trend toward miniaturization and higher energy density, efficient heat dissipation has become a critical design challenge for thermal management systems.</p><p>Thermal Interface Materials (TIMs) are specialized compounds placed between two surfaces (e.g., between a microprocessor and a heat sink) to improve heat transfer. They eliminate microscopic air pockets caused by surface roughness, replacing low thermal conductivity air (0.026 W/m·K) with a more efficient interface to reduce thermal resistance levels and enhance conduction.</p><h2>Applications of thermal interface material</h2><p>TIM materials are crucial for effective heat transfer in electronics systems, power electronics, and medical devices. They prevent overheating in CPUs, GPUs, LEDs, and high-power electronics [1], ensure reliability in <a href="https://www.idtechex.com/en/research-report/thermal-interface-materials/1011" target="_blank">automotive and advanced driver-assistance systems (ADAS)</a>, and maintain safety and accuracy in <a href="https://www.medicaldesignbriefs.com/component/content/article/23307-applying-metallic-thermal-interface-materials-for-medical-electronics" target="_blank">medical imaging, surgical equipment, and portable health monitors</a>, enhancing performance, reliability, and device longevity.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6838a54f28cdcf2275ba2f63_thermal-interface-material-tca-pcm-metal.webp" loading="lazy" alt="A chart comparing six types of TIM materials in terms of thermal conductivity, contact thermal resistance, pump-out, reusability, stress absorption, and replaceability. From top to bottom: thermal pad, thermal gel, thermal conductive adhesive (TCA), phase-change material (PCM), thermal grease, and metal solders." width="auto" height="auto"></div><figcaption>Common types of commercial TIMs and typical properties ©<a href="https://doi.org/10.3390/electronics13214287" target="_blank">Tu, Y., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p>TIMs come in various formulations and can be grouped into six main categories: thermal pads, thermal grease, thermal gels, thermally conductive adhesives (TCA), phase-change materials (PCM), and metal solders [2]. Apart from prefabricated thermal pads, the rest of the categories are compatible with TIM paste dispensing techniques such as syringe dispensing, <a href="https://www.voltera.io/blog/introduction-screen-printing">screen printing</a>, or <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">direct ink writing</a> (DIW).</p><h2>Thermal grease</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6838a4ef986722287e3b633b_thermal-interface-material-thermal-paste-microprocessor.webp" loading="lazy" alt="A hand applying thermal paste on a microprocessor using a spatula" width="auto" height="auto"></div><figcaption>Thermal paste being applied on a microprocessor</figcaption></figure><p>Thermal greases, also known as thermal compounds or pastes, are non-curing viscous liquids, usually consisting of a polymer oil (often synthetic or silicone-based materials) filled with thermally conductive particles like metal oxides and metal powders [3]. They typically exhibit bulk thermal conductivities between 2 W/m·K and 10 W/m·K [2]. More recent thermal pastes use inorganic fillers, such as aluminum oxide, zinc oxide, and silicon carbide, as well as metallic fillers, such as silver and copper, to enhance thermal conductivities up to 17 W/m·K [1].&nbsp;</p><p>A key advantage of thermal greases is their excellent conformability and low hardness. Thermal greases have no inherent bonding strength (they remain wet or semi-fluid), which allows them to flow readily and fill very thin interface areas on the order of <a href="https://krafab.com/thermal-interface-materials/" target="_blank">5 mils</a> (about 127 μm) or less.&nbsp;</p><p>However, a well-known drawback of thermal pastes is their tendency to migrate under thermal cycling. Repeated expansion or contraction of the interface (due to temperature swings and differing coefficients of thermal expansion) can cause the grease to be slowly pushed (“pump-out”) from the interface over time [3]. This pump-out of excess material or drying of thermal greases can lead to <a href="https://www.henkel-adhesives.com/ca/en/services/resources/white-papers-technical-papers/beyond-thermal-grease-enhancing-thermal-performance-and-reliability.html" target="_blank">performance degradation</a> in long-term use.</p><h3>Thermal gel</h3><p>Thermal gels are typically <a href="https://www.jointas-chemical.com/article/understanding-thermal-gel.html" target="_blank">one-part or two-part</a> formulations that result in an ultra-soft, gel-like polymer matrix filled with thermally conductive particles, similar to thermal pastes. Unlike standard thermal grease, which <a href="https://www.jointas-chemical.com/article/difference-between-thermal-grease-and-thermal-gel.html" target="_blank">does not cure</a>,&nbsp;thermal gels cure into a soft, rubbery solid and serve as effective thermal gap filler materials.</p><p>Because thermal gels are inherently cohesive, they resist pump-out and can handle mechanical vibration or thermal cycling more robustly [2]. This makes them popular in <a href="https://gravicgroup.com/en/thermal-gel/" target="_blank">automotive electronics</a> and other cases where shock or flex might be an issue — the gel fills the gap and also absorbs mechanical stress.</p><h3>Thermally conductive adhesives</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6838a60e47e67b974765793e_thermal-interface-material-thermally-conductive-adhesive.webp" loading="lazy" alt="A diagram depicting the heat conduction mechanism in thermally conductive adhesives (TCA), showing three zones: the hot surface, the conductive path (TCA layer), and the cold surface." width="auto" height="auto"></div><figcaption>Heat conduction mechanism of thermally conductive adhesives ©<a href="https://www.mdpi.com/2073-4360/13/19/3337" target="_blank">Alim, Md. A., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p>TCAs are polymer-based thermal interface materials that not only conduct heat but also mechanically bond components together. These thermal adhesives are usually epoxy-, silicone-, or acrylate-based adhesives loaded with thermally conductive fillers such as <a href="https://en.elaplus.cc/thermal-conductive-adhesive-suitable-for-electronic-and-semiconductor-applications/">alumina, boron nitride, or metallic particles</a>. Most commercial TCAs have thermal conductivities around 1-4 W/m·K, though some specialized formulations (with very high loadings of silver or novel fillers) report high thermal conductivity values above 10-20 W/m·K [2].&nbsp;</p><p>The biggest advantage of using TCAs is that a heat sink or component can be glued in place, eliminating the need for screws, clips, or clamps as a heat sink attachment method. This is valuable for small form factor designs or when mechanical retention is difficult (e.g., bonding a heat spreader onto a BGA package lid, or attaching an LED to a heat sink in a lighting module).</p><p>However, a cured adhesive is typically more rigid than a grease or gel. Many thermally conductive epoxies are filled with ceramic or metal powder and can be quite stiff. This means that while they hold parts firmly, if there is differential thermal expansion between the two bonded surfaces, the adhesive layer will experience shear stress. Over many thermal cycles, a brittle adhesive could crack or delaminate [4].</p><h2>Phase-change materials</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6838a65fd4c3b7151b5144f3_thermal-interface-material-phase-change-material.webp" loading="lazy" alt="A figure illustrating the phase changes microcapsules, categorized by core materials, shell materials, and thermal adhesives" width="auto" height="auto"></div><figcaption>Overview of phase change microcapsules ©<a href="https://www.oaepublish.com/articles/energymater.2023.04" target="_blank">Du B., et al</a>, <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank">CC BY 4.0</a></figcaption></figure><p>The base material of PCMs is often a wax or paraffin-like substance (sometimes blended with polymers), loaded with conductive filler particles. At room temperature, PCM is solid or highly viscous, which means it can be pre-applied to components without mess or flow. Once the electronic device heats up in operation and exceeds the phase-change temperature (typically 50-80 °C) [5], PCM softens to a semi-liquid state, flowing and filling in all microscopic air gaps at the interface. On cooling, PCM re-solidifies, holding the filler particles in place and preventing pump-out or dripping when the device is off.</p><p>Because PCMs do not cure chemically, they can pump-out if the device is cycled above the phase-change point without proper clamping – but in practice, well-designed PCM TIMs are formulated to resist excessive flow, and their ability to re-solidify provides greater long-term stability than uncured greases [2].</p><h2>Metal TIMs (solder)</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6838a6d8a7e49849fb2f4df7_thermal-interface-material-metal-solder-paste.webp" loading="lazy" alt="A printed circuit board with multiple ICs, showing solder paste dispensed on pins" width="auto" height="auto"></div><figcaption>Solder paste dispensed on a printed circuit board being reflowed</figcaption></figure><p>Metal TIMs in paste form are solder pastes used as thermal interfaces. They consist of fine metal alloy powders (e.g., <a href="https://ieeexplore.ieee.org/abstract/document/9816406" target="_blank">indium-based alloys</a> for high performance applications) suspended in a flux binder, similar to the solder pastes used in PCB assembly. They are dispensed using a thermal paste dispenser or similar precision equipment. Then the assembly is reflowed to melt the metal powder, creating a solid metal interface [6].</p><p>Metal solders have some of the lowest measured contact resistances (e.g., <a href="https://asmedigitalcollection.asme.org/IMECE/proceedings-abstract/IMECE2010/77/339779" target="_blank">0.00253 cm<sup> 2</sup> K/W</a>) and deliver optimal thermal performance. They are used in scenarios demanding extreme heat flux transfer, such as high-power or high-density electronics. For example, many high-end server and GPU chips use a solder TIM between the die and heat spreader to handle the heat load that a grease would struggle with [7].</p><p>However, the excellent thermal performance of metal solders comes with trade-offs of mechanical properties: Metals have high stiffness and low compliance, so a solder layer will not accommodate differential thermal expansion well. Similar to conductive adhesives, if the two bonded parts expand at different rates, stresses can build up in the solder, potentially causing fatigue or cracks over many thermal cycles [5].</p><h2>Conclusion</h2><p>Thermal interface materials are an indispensable component in the design of modern electronic and electrical systems. Different types of thermal interface materials — grease, gel, adhesive, PCM, solder — offer unique thermal and mechanical advantages. Selecting the optimal thermal management solution involves a multifaceted trade-off that balances thermal conduction and mechanical performance, manufacturability, costs, and design complexity.&nbsp;</p><p>Interested in the applications of TIM materials? Explore these resources:</p><ul><li>Blog: <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova">Print Multilayer Flexible and Stretchable Circuits with NOVA</a></li><li>Report: <a href="https://www.idtechex.com/en/research-report/thermal-interface-materials/1011" target="_blank">Thermal Interface Materials 2024-2034: Technologies, Markets, and Forecasts</a></li><li>Open course: <a href="https://youtu.be/w6R6V1Mpz7s?si=p39yNQ5PcCgPo-5I" target="_blank">Thermal Modeling and Heat Sinking</a></li></ul><p>Are you dispensing thermal interface materials? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=thermal-interface-material&utm_content=book-a-meeting">Book a meeting</a> to speak with one of our technical representatives.</p><h2>References</h2><p>[1] Xing, W., Xu, Y., Song, C., &amp; Deng, T. (2022). Recent Advances in Thermal Interface Materials for Thermal Management of High-Power Electronics. <em>Nanomaterials</em>, 12(19), 3365. <a href="https://doi.org/10.3390/nano12193365" target="_blank">https://doi.org/10.3390/nano12193365</a>.</p><p>[2] Tu, Y., Liu, B., Yao, G., Luo, H., Jia, X., Du, J., &amp; Xu, C. (2024). A Review of Advanced Thermal Interface Materials with Oriented Structures for Electronic Devices. <em>Electronics</em>, 13(21), 4287–4287. <a href="https://doi.org/10.3390/electronics13214287" target="_blank">https://doi.org/10.3390/electronics13214287</a>.</p><p>[3] Prasher, R. (2006). Thermal Interface Materials: Historical Perspective, Status, and Future Directions. <em>Proceedings of the IEEE</em>, 94(8), 1571–1586. <a href="https://doi.org/10.1109/jproc.2006.879796" target="_blank">https://doi.org/10.1109/jproc.2006.879796</a>.</p><p>[4] Zhou, Y., Wu, S., Long, Y., Zhu, P., Wu, F., Liu, F., Murugadoss, V., Winchester, W., Nautiyal, A., Wang, Z., &amp; Guo, Z. (2020). Recent Advances in Thermal Interface Materials. <em>ES Materials &amp; Manufacturing</em>. <a href="https://doi.org/10.30919/esmm5f717" target="_blank">https://doi.org/10.30919/esmm5f717</a>.</p><p>[5] F. Sarvar, Whalley, D. C., &amp; Conway, P. (2006). Thermal Interface Materials - A Review of the State of the Art. <a href="https://doi.org/10.1109/estc.2006.280178" target="_blank">https://doi.org/10.1109/estc.2006.280178</a>.</p><p>[6] Lee, D. W., Mayberry, R., Mackie, A., Hable, B., Heller, D., Jarrett, B., Zhao, X., &amp; Nash, T. (2022). Optimizing Reflowed Solder TIM (sTIMs) Processes for Emerging Heterogeneous Integrated Packages. 2022. <em>IEEE 72nd Electronic Components and Technology Conference (ECTC)</em>, 1228–1237. <a href="https://doi.org/10.1109/ectc51906.2022.00197" target="_blank">https://doi.org/10.1109/ectc51906.2022.00197</a>.</p><p>[7] Razeeb, K. M., Dalton, E., Graham, &amp; Robinson, A. J. (2017). Present and future thermal interface materials for electronic devices. <em>International Materials Reviews</em>, 63(1), 1–21. <a href="https://doi.org/10.1080/09506608.2017.1296605" target="_blank">https://doi.org/10.1080/09506608.2017.1296605</a>.</p>

What Is Thermal Interface Material (TIM)?

Understand TIM material for thermal management. Learn the pros and cons of pads, grease, gel, TCA, PCM, and metal solder interfaces for hot-running devices.

Thermal Interface Material (TIM): Selection Guide

Explore thermal interface materials (TIM), including thermal pastes, thermal gels, conductive adhesives (TCA), phase-change materials (PCM), and metal solders.

<p id="">Researchers and product developers continually push the limits of precision and resolution in material dispensing. Dot dispensing in electronics and other advanced fields such as additive manufacturing, chemical engineering, and biomedicine provides the fine control needed for cutting-edge applications, enabling features such as fine <a href="https://www.voltera.io/use-cases/applications/solder-paste-printing" id="">solder paste application</a>, DNA microarrays (a kind of biochip), or <a href="https://www.voltera.io/use-cases/applications/adhesive-dispensing" id="">adhesive</a> micro dots.</p><h2 id="">How dot dispensing works</h2><p id="">In dot dispensing (a form of drop-on-demand printing), a small volume of functional material is ejected from a nozzle to form a droplet (”dot”) that lands on a substrate at a specified location. Each dot is typically on the order of microliters, nanoliters, or even picoliters in volume.&nbsp;</p><p id="">The process is digitally controlled: each droplet is generated only when and where needed, allowing precise patterning and minimizing waste. By adjusting process parameters (such as pressure pulses or actuator voltage), the system controls the volume of each drop and thus the dot size on the substrate.</p><h2 id="">Applications of dot dispensing</h2><p id="">The applications of dot dispensing include microelectronics packaging (e.g., solder paste, conductive adhesives), flexible printed electronics, microfluidics fabrication, biomaterial and cell-based bioprinting, LED phosphor dispensing, underfill encapsulation, and the construction of microstructured sensors and actuators for electronic skin and wearable technology. They provide high accuracy, repeatability, and scalability critical for complex device fabrication and advanced material development [1].</p><h2 id="">Types of dot dispensing machines</h2><p id="">There are several engineering approaches to generate and dispense tiny dots. Based on one classification framework of Lee J M, et al. [2], dot dispensing mechanisms fall into two broad categories:&nbsp;</p><ul id=""><li id="">Material jetting: A non-contact method that uses actuation mechanisms such as piezoelectric or solenoid jet valves to eject discrete droplets</li><li id="">Material extrusion: A contact-based method where material is deposited through pressure-driven flow, including pneumatic time-pressure and positive displacement systems</li></ul><p id="">Each category is suited to a different viscosity range and precision level.</p><h2 id="">Material jetting&nbsp;</h2><h3 id="">Piezoelectric inkjet dot dispensing machines</h3><p id="">Piezoelectric inkjet dispensers use a piezoelectric actuator to create a pressure pulse in a small ink chamber, ejecting a droplet through a fine orifice. They produce extremely small droplets (single picoliters), enabling high-resolution patterning and precise application in the form of thin, accurate deposit dots and lines [3][4].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/682f6834d9779ec4d984d983_dot-dispensing-piezoelectric-actuated-jetting-system.webp" loading="lazy" alt="A labelled diagram of a piezoelectric actuated jetting system" width="auto" height="auto" id=""></div><figcaption id="">A piezoelectric actuated jetting system © <a href="https://doi.org/10.4071/001c.127407" target="_blank" id="">Agarwal, S</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><p id="">The limitation of piezoelectric inkjet, however, is that they impose strict ink property requirements: typically a viscosity below 40 cP and surface tension in the 20-70 mN/m-1 range for reliable jetting [5]. As such, piezoelectric inkjet dispensers are only suitable for micro volume dispensing of low-viscosity functional inks such as conductive polymers and nanoparticle inks [3].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/682f68aac31d1f7199177c78_dot-dispensing-droplet-quality-piezoelectric-valve.webp" loading="lazy" alt="Droplet quality of an epoxy adhesive material with ~300 µm diameter jetted by a piezo-driven dispense valve from a dispense height of 2 mm from the substrate" width="auto" height="auto" id=""></div><figcaption id="">Quality of epoxy adhesive droplets with ~300 µm diameter jetted by a piezo-driven dispense valve © <a href="https://doi.org/10.4071/001c.127407" target="_blank" id="">Agarwal, S</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><h3 id="">Solenoid jetting dot dispensing machines</h3><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/682f68d25591acdbdf9a4f81_dot-dispensing--solenoid-valve-jetting-system.webp" loading="lazy" alt="" width="auto" height="auto" id=""></div><figcaption id="">A pneumatic-solenoid valve droplet dispensing system, adapted from © <a href="https://mnsl-journal.springeropen.com/articles/10.1186/s40486-014-0005-8#:~:text=The%20measured%20droplet%20volume%20,to%20985%C2%A0nL%20because%20the%20maximum" id="">Lee, S., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" id="">CC BY 4.0</a></figcaption></figure><p id="">Different from a piezo-actuated valve dispenser, where a piezoelectric stack or bending element drives the needle open and closed, in a solenoid jet valve, a coil generates a magnetic force to lift the valve needle off its seat momentarily, allowing fluid to jet out until the spring or magnetic force closes it again.</p><p id="">Similar to piezoelectric jetting systems, solenoid jetting dispensers excel at very high-speed dotting (up to kHz firing rates) and tiny dot sizes (tens of microns), but can handle viscosities <a href="https://tameson.com/pages/fluid-viscosity" target="_blank" id="">up to about 40 cP</a>. Although <a href="https://utw10945.utweb.utexas.edu/Manuscripts/2013/2013-40-Yang.pdf" target="_blank" id="">researchers</a> have been experimenting with pushing jetting into the higher viscosity range, challenges of pattern fidelity remain to be solved.&nbsp;</p><p id="">In addition, a material jetting system is more complex than a simple time-pressure syringe. It requires a precision-machined valve assembly and a dedicated driver (for the solenoid or piezo). These systems are often more expensive per dispense head than a basic pneumatic time-pressure dispenser, limiting their scalability.</p><h2 id="">Material extrusion&nbsp;</h2><h3 id="">Pneumatic time-pressure dot dispensing machines</h3><p id="">A time-pressure pneumatic dispenser uses a controlled pressure (air or inert gas) applied to a fluid reservoir to push material through a nozzle. By adjusting pressure and valve open time, discrete droplets can be dispensed [6].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/682f6933a19e839f5635996e_dot-dispensing-pneumatic-time-pressure-dispenser.webp" loading="lazy" alt="A labelled diagram of pneumatic time-pressure dispenser" width="auto" height="auto" id=""></div><figcaption id="">A pneumatic time-pressure dispenser © <a href="https://www.researchgate.net/publication/363376844_Experimental_Study_of_the_Jetting_Behavior_of_High-Viscosity_Nanosilver_Inks_in_Inkjet-Based_3D_Printing" target="_blank" id="">Xiao, X., et al</a>., <a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><p id="">Compared to piezo or microvalve systems, pneumatic dispensers tolerate higher viscosity fluids than inkjet heads (typically 100-100,000 cP), making them versatile in their applications. They are suitable for thick adhesives, silicone sealants, solder pastes, or polymer gels that piezo inkjets cannot eject [7].&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/682f6983f2725d3766e254f6_dot-dispensing-pneumatic-dispenser-tumer-cells.webp" loading="lazy" alt="Top row, left to right: Diagram of a pneumatic dispensing system; chart showing GelMA concentration versus dispensing time; chart showing dispensing time versus diameter of GelMA hydrogel beads (GHBs). Bottom row, left to right: Micrograph of tumor cell-laden GelMA beads dispensed by the pneumatic dispenser; chart showing GelMA concentration versus printed temperature; chart showing temperature versus modulus." width="auto" height="auto" id=""></div><figcaption id="">GelMa hydrogel beads containing tumor cells dispensed by a pneumatic dispensing system, © <a href="https://www.sciencedirect.com/science/article/pii/S0264127522007742" target="_blank" id="">Wei, X., et al</a> [8],<a href="https://creativecommons.org/licenses/by/4.0/" target="_blank" id="">CC BY 4.0</a></figcaption></figure><p id="">However, the precision and minimum dot size achievable by pneumatic dispensers are more limited. The dispensed volume depends on several factors (pressure level, time, fluid viscosity, nozzle diameter, and even air compressibility) [9], which makes ultra-fine control challenging. Without additional feedback or mechanical pinch-off, achieving very small, consistent dot volumes (in the low-nanoliter range) is difficult due to variability in how the fluid stream breaks off [1].</p><h3 id="">Positive displacement dot dispensing machines</h3><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6842f5eaf8bcf80f9ec4104d_dot-dispensing-solder-paste-voltera-nova.webp" loading="lazy" alt="Results of solder paste dots dispensed by Voltera’s NOVA materials dispensing system with different print settings" width="auto" height="auto" id=""></div><figcaption id="">Solder dots dispensed by Voltera’s NOVA materials dispensing system under different settings</figcaption></figure><p id="">Positive displacement dot dispensing machines use mechanical actuators (e.g., pistons, auger/screws) to directly displace fluid, eliminating air compressibility errors inherent in pneumatic systems. This enables superior volumetric accuracy (&lt; about 1.5% coefficient of variation for 100 nL volumes) and precise control over high-viscosity fluids (up to 1,000,000 cP) [10].</p><p id="">Extrusion-based <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> equipment, such as <a href="http://www.voltera.io/nova" id="">NOVA</a> (pressure-feedback positive displacement dispensing), falls into this category, capable of accommodating highly viscous, paste-like inks that are orders of magnitude thicker than inks for inkjet dispensers. For example, silver-filled conductive adhesives with nano- or micro-particles, or solder paste with metal alloy powder, can be dispensed by DIW systems when they would clog a fine inkjet nozzle. The ability to deposit such high-solids, thixotropic fluids is a key advantage of extrusion-based dot dispensing [9].</p><h2 id="">Conclusion</h2><p id="">Dot dispensing technology continues to evolve, expanding its scope into new materials and applications. Improvements in actuator design, fluidics, and control software are pushing the boundaries of what can be dispensed in tiny dot form. By choosing the appropriate dispensing mechanism for a given material and feature size, scientists and engineers can reliably deposit microscopic amounts of material exactly where needed, enabling the fabrication of next-generation devices and materials, one tiny drop at a time.</p><p id="">Want to learn more about materials dispensing? Explore these resources:</p><ul id=""><li id="">Blog: <a href="https://www.voltera.io/blog/precision-fluid-dispensing-systems">What Are Precision Fluid Dispensing Systems?</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/what-is-viscosity">What Is Viscosity?</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/droplet-dispensing">What Is Droplet Dispensing?</a></li><li id="">Video: <a href="https://www.youtube.com/watch?v=JwtJUNKQ450" target="_blank">Dot, Dot, Dot...Optimized Dispensing for Silver-Filled Conductive Epoxy Adhesives</a></li></ul><p id="">Ready to discuss your dot dispensing needs? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=dot-dispensing&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with one of our technical representatives.</p><h2 id="">References</h2><p id="">[1] Lee, S., Choi, I. H., Kim, Y. K., &amp; Kim, J. (2014). Velocity control of nanoliter droplets using a pneumatic dispensing system. <em id="">Micro and Nano Systems Letters</em>, 2(1). <a href="https://doi.org/10.1186/s40486-014-0005-8" target="_blank" id="">https://doi.org/10.1186/s40486-014-0005-8</a>.&nbsp;</p><p id="">[2] Lee, J. M., Sing, S. L., Zhou, M., &amp; Yeong, W. Y. (2018). 3D bioprinting processes: A perspective on classification and terminology. <em id="">International Journal of Bioprinting</em>, 4(2). <a href="https://doi.org/10.18063/ijb.v4i2.151" target="_blank" id="">https://doi.org/10.18063/ijb.v4i2.151</a>.</p><p id="">[3] Bernasconi, R., Brovelli, S., Viviani, P., Soldo, M., Giusti, D., &amp; Magagnin, L. (2021). Piezoelectric Drop‐On‐Demand Inkjet Printing of High‐Viscosity Inks. <em id="">Advanced Engineering Materials</em>, 24(1), 2100733. <a href="https://doi.org/10.1002/adem.202100733" target="_blank" id="">https://doi.org/10.1002/adem.202100733</a>.</p><p id="">[4] Ng, W. L., Lee, J. M., Yeong, W. Y., &amp; Win Naing, M. (2017). Microvalve-based bioprinting – process, bio-inks and applications. <em id="">Biomaterials Science</em>, 5(4), 632–647. <a href="https://doi.org/10.1039/c6bm00861e" target="_blank" id="">https://doi.org/10.1039/c6bm00861e</a>.&nbsp;</p><p id="">[5] Tsai, H.-L., Hwang, W.-S., Wang, J.-K., Peng, W.-C., &amp; Chen , S.-H. (2015). Fabrication of Microdots Using Piezoelectric Dispensing Technique for Viscous Fluids. <em id="">Materials</em>, 8(10), 7006–7016. <a href="https://doi.org/10.3390/ma8105355" target="_blank" id="">https://doi.org/10.3390/ma8105355</a>.</p><p id="">[6] Durham, M., Wade, G., Judd, B., &amp; Boggiatto, J. (n.d.). Process Optimization for Fine Feature Solder Paste Dispensing. Retrieved May 9, 2025, from <a href="https://www.ipc.org/system/files/technical_resource/E40%26S16_01%20-%20Maria%20Durham.pdf" target="_blank" id="">https://www.ipc.org/system/files/technical_resource/E40%26S16_01%20-%20Maria%20Durham.pdf</a>.</p><p id="">[7] Xiao, X., Li, G., Liu, T., &amp; Gu, M. (2022). Experimental Study of the Jetting Behavior of High-Viscosity Nanosilver Inks in Inkjet-Based 3D Printing. <em id="">Nanomaterials</em>, 12(17), 3076. <a href="https://doi.org/10.3390/nano12173076" target="_blank" id="">https://doi.org/10.3390/nano12173076</a>.&nbsp;</p><p id="">[8] Wei, X., Huang, B., Chen, K., Fan, Z., Wang, L., &amp; Xu, M. (2022). Dot extrusion bioprinting of spatially controlled heterogenous tumor models. <em id="">Materials &amp; Design</em>, 223, 111152. <a href="https://doi.org/10.1016/j.matdes.2022.111152" target="_blank" id="">https://doi.org/10.1016/j.matdes.2022.111152</a>.&nbsp;</p><p id="">[9] Polychronopoulos, N. D., &amp; Angeliki Brouzgou. (2024). Direct Ink Writing for Electrochemical Device Fabrication: A Review of 3D-Printed Electrodes and Ink Rheology. <em id="">Catalysts</em>, 14(2), 110–110. <a href="https://doi.org/10.3390/catal14020110" target="_blank" id="">https://doi.org/10.3390/catal14020110</a>.&nbsp;</p><p id="">[10] Ando, T., Hirano, M., Ishige, Y., &amp; Adachi, S. (2016). Precise Dispensing Technology Using Electroformed Tubes for Micro-Volume Blood Diagnosis. <em id="">IEEE journal of translational engineering in health and medicine</em>, 6, 2800506. <a href="https://doi.org/10.1109/JTEHM.2018.2852664" target="_blank" id="">https://doi.org/10.1109/JTEHM.2018.2852664</a>.&nbsp;</p>

What Is Dot Dispensing?

Dive into the world of dot dispensing, from piezoelectric material jetting and pneumatic time-pressure dispensers to hybrid microvalve systems.

<p id="">Functional inks are the backbone of printed electronics, transforming ordinary substrates like plastic, paper, or textiles into smart, interactive devices. Functional inks add specialized properties — conductivity, sensing, or thermal regulation — to create circuits that power everything from wearable sensors to electromagnetic interference (EMI) shielding.</p><h2 id="">Types of functional inks</h2><p id="">Functional inks are typically divided into three categories <a href="https://www.boydcorp.com/blog/fundamentals-functional-inks-part-1.html" id="">based on their main use</a>: conductive, non-conductive, and specialty inks.</p><h3 id="">Conductive inks</h3><p id=""><a href="https://www.voltera.io/blog/conductive-inks" id="">Conductive ink</a> forms the electrical connection of printed electronics. These inks are composed of conductive fillers — such as silver, copper, or carbon — dispersed in a liquid vehicle containing binders, solvents, and additives that determine the viscosity, surface tension, wettability, and adhesion of the ink [1].&nbsp;</p><h4 id="">Metal-organic decomposition (MOD) inks</h4><p id="">MOD ink contains metal-organic precursors dissolved in organic solvents, or complexing agents like amines or carboxylic acids. When heated, these compounds break down, forming a pure conductive metal layer. MOD inks are compatible with a variety of printing technologies, including <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> (DIW), <a href="https://www.voltera.io/blog/introduction-inkjet-technology" id="">inkjet</a>, aerosol jet, and <a href="https://www.voltera.io/blog/introduction-screen-printing" id="">screen printing</a> [2].&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67f7ed22312283a6430378f8_functional-inks-printable-metal-organic-decomposition.webp" loading="lazy" alt="six screen-printable MOD inks showing metal precursor, substrate, sintering temperature, and resistivity" width="auto" height="auto" id=""></div><figcaption id="">Samples of screen-printable MOD inks [2], © Kell, A., et al</figcaption></figure><p id="">These inks stand out because they can be processed at lower temperatures (usually below 150°C), making them perfect for flexible substrates like plastics. Silver MOD inks can achieve very high conductivity, similar to solid silver, after heating at just 90°C. Copper MOD inks also perform well but need special environments to prevent oxidation [1].&nbsp;</p><p id="">However, MOD inks typically experience significant volume loss after solvent evaporation, potentially leading to voids and conductivity issues, and require multiple print-and-sinter cycles to achieve the desired conductivity [2].</p><h4 id="">Nanoparticle metal inks</h4><p id="">Nanoparticle inks use tiny metal particles (silver, copper, platinum, or gold) suspended in solvents. These inks offer excellent conductivity due to their high metal content (70-97.5% by weight). They're popular because they quickly solidify under laser or photonic sintering, making them great for flexible electronics [1][3].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67f7ed6470e235094f7e933b_functional-inks-formulating-particle-ink-mod-ink.webp" loading="lazy" alt="Processes for formulating particle ink and MOD ink" width="auto" height="auto" id=""></div><figcaption id="">Processes for formulating particle ink and MOD ink [4] © Choi, Y., et al</figcaption></figure><p id="">However, nanoparticle inks can be tricky to produce. They often contain chemicals (surfactants) to prevent particle clumping, which must be removed at high temperatures, making it a challenge when working with heat-sensitive substrates like plastics [1].</p><h3 id="">Non-conductive inks</h3><p id="">Non-conductive inks don’t carry electricity but are crucial for protecting and supporting electronic circuits. These inks include encapsulants to protect against moisture, bioinks that are safe for human skin, insulating inks for electrical isolation, and adhesive inks for bonding.</p><h4 id="">Adhesive inks</h4><p id="">Adhesives hold layers of printed electronics together or attach electronic components directly to printed surfaces. Recent innovations include silicone-based adhesive inks that quickly cure without shrinking, ensuring stable and durable structures. This advancement greatly reduces curing time, prevents distortion, and improves adhesion between layers, solving common issues with traditional adhesives​ formulations [5].</p><h3 id="">Specialty inks</h3><p id="">Specialty inks provide unique capabilities beyond electrical conductivity. Thermal inks help regulate temperature, enabling products like self-warming clothing or anti-fogging mirrors. Optical inks control light for anti-glare screens or OLED displays. EMI shielding inks, typically made with silver or carbon, protect electronics in industries ranging from consumer electronics to aerospace.</p><h4 id="">Glass inks</h4><p id="">Glass ink is an exciting specialty ink used for advanced optical applications, like lenses or fiber optics. Recent research demonstrated how DIW technology can print water-sensitive borosilicate glass inks using fine glass powder mixed in hydrogel. Although currently opaque due to air pockets formed during heat treatment, ongoing research aims to make printed glass clearer, unlocking its potential for high-quality optical devices [6].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67f7ed88e2ad07a788c152b9_functional-inks-diw-printing-glass-ink.webp" loading="lazy" alt="Photo with glass ink formulated using DIW technology on the left and scanning electron microscope micrograph of the glass ink on the right" width="auto" height="auto" id=""></div><figcaption id="">Glass ink formulated using DIW technology, photo and scanning electron microscope micrograph [6] © Nan, B.,et al</figcaption></figure><h2 id="">Choosing the right substrate for functional inks</h2><p id="">The choice of material you print on significantly impacts ink performance. Rigid substrates like glass or ceramics tolerate high temperatures, and are ideal for MOD inks in precision electronics. Flexible substrates like polyimide films, paper, or textiles match well with lower-temperature inks, enabling flexible and wearable electronics.</p><h2 id="">Formulating functional DIW inks</h2><p id="">Direct ink writing has been identified as the most versatile additive manufacturing technique for developing functional inks, allowing single-layer microscale circuits to multi-material, multilayer structures [7].</p><p id="">Successful DIW inks balance printability with functionality, which involves careful control of ink flow (rheology), ingredients, and curing [8].</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67f7edbf6b3c34db09eca398_functional-inks-diy-carbon-resistive-ink.webp" loading="lazy" alt="A cartridge containing carbon resistive ink formulated by Voltera’s Applications team" width="auto" height="auto" id=""></div><figcaption id="">Carbon resistive ink formulated by Voltera’s Applications team</figcaption></figure><h3 id="">Rheological properties</h3><p id="">To print smoothly, inks must flow easily when pressure is applied but quickly stiffen after printing. This characteristic, known as shear-thinning, typically involves adding fine particles like silica or ceramic powders, which temporarily separate under pressure and quickly regroup afterward, helping the ink hold its shape [8].&nbsp;</p><h3 id="">Ink composition</h3><p id="">Ink composition is a careful balance of binders, solvents, and functional additives tailored to the ink’s end use. For example, while conductive inks prioritize high filler loading for electron flow, adhesives emphasize polymer elasticity.&nbsp;</p><h3 id="">Curing and post-processing</h3><p id="">Different inks require specific curing methods after deposition. For instance, air-dry inks solidify as solvents evaporate, while UV-cure inks rapidly harden under ultraviolet light. Choosing an appropriate curing method is essential to maintain the ink's intended functionality.</p><h2 id="">Functional ink supplier and partnership with Voltera</h2><p id="">Major suppliers include <a href="https://www.acimaterials.com/" id="">ACI Materials</a>, <a href="https://www.creativematerials.com/" id="">Creative Materials</a>, <a href="https://novacentrix.com/" id="">NovaCentrix</a>, and <a href="https://www.vfpinc.com/products/fabrication-solutions/" id="">VFP</a>, offering everything from medical-grade nano inks to high-recovery adhesives.</p><p id="">At Voltera, we regularly create specialized electronics with functional inks, including:</p><ul id=""><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet" id="">Electroluminescent display</a> (optical ink)</li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-magnesium-zinc-battery-saral-inks-pet" id="">Flexible multilayer battery</a> (insulating, metal, and adhesive inks)</li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-silver-conductive-ink-cotton-fabric" id="">Wearable heating element</a> (stretchable resistive ink)</li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="">ECG electrodes</a> (biocompatible gold ink)</li></ul><h2 id="">Conclusion</h2><p id="">Functional inks are reshaping printed electronics, enabling lightweight, flexible, and multi-functional products. From precise MOD inks to specialty glass and adhesive inks, these materials power innovation across IoT, healthcare, wearables, and beyond. With advancements continuing, the future holds greener, more efficient inks driving the electronics of tomorrow.</p><p id="">Want to learn more? Explore these resources:</p><ul id=""><li id="">Blog: <a href="https://www.voltera.io/blog/ultimate-guide-choosing-materials-new-electronics-product" id="">The Ultimate Guide to Choosing Materials for a New Electronics Product</a></li><li id="">Video: <a href="https://youtu.be/UhzsusIzwY0" id="">Developing a Custom Carbon Ink for Printing a Variable Resistor on PET</a></li><li id="">Application: <a href="https://www.voltera.io/use-cases/applications/functional-ink-development">Functional ink development</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/developing-custom-carbon-ink-printing-variable-resistor-pet" id="">Developing a Custom Carbon Ink for Printing a Variable Resistor on PET</a></li></ul><p id="">Want to discuss your own functional ink development needs? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=functional-ink&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with a technical representative.</p><h2 id="">References</h2><p id="">[1 ] Douglas, S. P., Mrig, S., &amp; Knapp, C. E. (2021). MODs vs. NPs: Vying for the Future of Printed Electronics.<em id=""> Chemistry – a European Journal</em>, 27(31), 8062–8081. <a href="https://doi.org/10.1002/chem.202004860" id="">https://doi.org/10.1002/chem.202004860</a>.</p><p id="">[2] Kell, A. J., Wagner, K., Liu, X., Lessard, B. H., &amp; Paquet, C. (2023). Advanced Applications of Metal–Organic Decomposition Inks in Printed Electronics. <em id="">ACS Applied Electronic Materials</em>. <a href="https://doi.org/10.1021/acsaelm.3c00910" id="">https://doi.org/10.1021/acsaelm.3c00910</a>.</p><p id="">[3] de Souza, F. M., &amp; Gupta, R. K. (2023). Smart Multifunctional Nano-inks: Fundamentals and Emerging Applications, <a href="https://doi.org/10.1016/B978-0-323-91145-0.00004-9" id="">https://doi.org/10.1016/B978-0-323-91145-0.00004-9</a> p. 659.</p><p id="">[4] Choi, Y., Seong, K., &amp; Piao, Y. (2019). Metal−Organic Decomposition Ink for Printed Electronics. <em id="">Advanced Materials Interfaces</em>, 6(20). <a href="https://doi.org/10.1002/admi.201901002" id="">https://doi.org/10.1002/admi.201901002</a>.&nbsp;</p><p id="">[5] Garcia, V. J., G. M. Fazley Elahee, Collera, A. K., Thornton, T., Cheng, X., Rohan, S., Howard, E. L., Espera, A. H., &amp; Advincula, R. C. (2023). On the direct ink write (DIW) 3D printing of styrene-butadiene rubber (SBR)-based adhesive sealant. <em id="">MRS Communications</em>, 13(6), 1266–1274. <a href="https://doi.org/10.1557/s43579-023-00436-0" id="">https://doi.org/10.1557/s43579-023-00436-0</a>.</p><p id="">[6] Nan, B., Przemysław Gołębiewski, Ryszard Buczyński, Galindo-Rosales, F. J., &amp; Ferreira, F. (2020). Direct Ink Writing Glass: A Preliminary Step for Optical Application. <em id="">Materials</em>, 13(7), 1636–1636. <a href="https://doi.org/10.3390/ma13071636" id="">https://doi.org/10.3390/ma13071636</a>.</p><p id="">[7] Yang, G., Sun, Y., Limin qin, Li, M., Ou, K., Fang, J., &amp; Fu, Q. (2021). Direct-ink-writing (DIW) 3D printing functional composite materials based on supra-molecular interaction. <em id="">Composites Science and Technology</em>, 215, 109013. <a href="https://doi.org/10.1016/j.compscitech.2021.109013" id="">https://doi.org/10.1016/j.compscitech.2021.109013</a>.</p><p id="">[8] De Smedt, S., Attaianese, B., &amp; Cardinaels, R. (2024). Direct ink writing of particle-based multiphase materials: From rheology to functionality. <em id="">Current Opinion in Colloid &amp; Interface Science</em>, 75, 101889. <a href="https://doi.org/10.1016/j.cocis.2024.101889" id="">https://doi.org/10.1016/j.cocis.2024.101889</a>.</p>

What Are Functional Inks?

Explore functional inks, from ingredients, uses and suppliers to applications in energy storage, flexible displays, biocompatible electronics and more.

What Are Functional Inks

<p id="">In this webinar, our Applications Lead <a href="https://ca.linkedin.com/in/thomas-p-b9ba01192" id="">Thomas Pol</a> teamed up with <a href="https://www.linkedin.com/in/rudresh-rudy-ghosh-phd-89463a4b" id="">Dr. Rudresh (“Rudy”) Ghosh</a> from NovaCentrix to explore printed electronics using silver conductive inks. The webinar covered Voltera’s two additive electronics platforms – V-One and NOVA – followed by an in-depth presentation on silver ink technology and a live Q&amp;A with the audience. ​</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=LgW3Ek7EqXc"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/LgW3Ek7EqXc" title="Webinar: Printing Electronics with Silver Conductive Inks"></iframe></div></figure><h2 id="">Webinar highlights</h2><h3 id="">Overview of Voltera printers&nbsp;</h3><h4 id="">V-One</h4><p id=""><a href="https://www.voltera.io/products/v-one?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=v-one" id="">V-One</a> is a compact desktop PCB printer for rapid prototyping on rigid boards. It dispenses conductive ink to print circuit patterns and cures them with a built-in heated bed. V-One can also apply solder paste and drill through holes for vias, enabling double-sided PCB prototypes.&nbsp;</p><h4 id="">NOVA</h4><p id=""><a href="https://www.voltera.io/products/nova?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=nova" id="">NOVA</a> is a materials dispensing system for flexible and stretchable electronics​. It can print on flexible, stretchable, conformable, and biocompatible substrates, as well as rigid substrates like <a href="https://store.voltera.io/search?q=%22fr1%22&options%5Bprefix%5D=last&filter.p.m.custom.product_type=Substrates&sort_by=relevance" id="">FR1</a>, <a href="https://store.voltera.io/search?q=%22fr4%22&options%5Bprefix%5D=last&filter.p.m.custom.product_type=Substrates&sort_by=relevance" id="">FR4</a>, and silicon wafers with a wide range of screen-printable inks (<a href="https://store.voltera.io/search?q=silver&options%5Bprefix%5D=last&filter.p.m.custom.product_type=Inks&sort_by=relevance" id="">silver</a>, gold, <a href="https://store.voltera.io/search?q=%22copper+ink%22&options%5Bprefix%5D=last" id="">copper</a>, <a href="https://store.voltera.io/search?q=%22carbon+ink%22&options%5Bprefix%5D=last" id="">carbon</a>, etc.).</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67ed4a28bad696dda4c28fe1_webinar-recap-printing-electronics-silver-projects.webp" loading="lazy" alt="Four projects printed with NOVA, including a 4-layer display printed with electroluminescent ink, a 2-layer EDG electrode printed with gold and silver ink, a project with silver ink printed directly on fabric, and a 7-layer flexible battery printed using a suite of battery inks" width="auto" height="auto" id=""></div><figcaption id="">Projects printed with the NOVA material dispensing system</figcaption></figure><p id="">Example projects printed with NOVA include:</p><ul id=""><li id="">Stretchable circuit: <a href="https://www.voltera.io/use-cases/white-papers/printing-silver-conductive-ink-cotton-fabric?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=white-paper" id="">Silver ink printed directly on cotton fabric</a>&nbsp;</li><li id="">Flexible multilayer circuit: <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=electroluminescent-project" id="">Four-layer display printed with electroluminescent ink</a></li><li id="">Conformable multilayer circuit: <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=wearable-sensors" id="">Two-layer ECG electrodes printed with gold and silver ink</a></li><li id="">Flexible multilayer circuit: <a href="https://www.voltera.io/use-cases/white-papers/printing-magnesium-zinc-battery-saral-inks-pet?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=seven-layer-flexible-battery" id="">Seven-layer flexible battery printed with a battery ink suite</a></li></ul><h3 id="">Guest presentation: Silver conductive inks</h3><p id="">Dr. Ghosh presented an in-depth look at conductive inks, focusing on silver-based formulations. He explained how material properties such as particle size, solvent composition, and binder selection impact ink performance. Compared to copper, silver inks offer higher conductivity, lower oxidation risk, and easier processing, making them ideal for prototyping and flexible electronics.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67ed4a5e719f1ab0bcc1c9c0_webinar-recap-printing-electronics-silver-novacentrix-ink.webp" loading="lazy" alt="NOVA dispensing NovaCentrix’s HPS-U11 Silver Nanoparticle Ink on Kapton" width="auto" height="auto" id=""></div><figcaption id="">NOVA printing NovaCentrix’s HPS-U11 Silver Nanoparticle Ink on Kapton</figcaption></figure><p id="">Dr. Ghosh also introduced <a href="https://novacentrix.com/product/hps-u11-silver-nanoparticle-ink/" id="">NovaCentrix’s HPS U11 Silver Nanoparticle Ink</a>, optimized for <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing</a> with:</p><ul id=""><li id="">High metal loading for lower sheet resistance</li><li id="">Fine resolution and minimal line spreading</li><li id="">Low curing temperature (around 140 °C)</li><li id="">Strong adhesion on both rigid and flexible substrates</li></ul><h3 id="">Live Q&amp;A</h3><p id="">After the presentations, Tom and Dr. Ghosh answered audience questions. Key questions included:</p><ul id=""><li id=""><strong id="">Q:</strong> Can NOVA’s software be accessed without purchasing the machine?</li><li id=""><strong id="">A:</strong> No, it comes included with the NOVA printer (at no extra cost).</li></ul><ul id=""><li id=""><strong id="">Q</strong>: Can I print circuits on fabric?</li><li id=""><strong id="">A</strong>: Yes. NOVA’s stretchable silver inks have been successfully printed on fabric. We have a <a href="https://www.voltera.io/use-cases/white-papers/printing-silver-conductive-ink-cotton-fabric?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=white-paper" id="">white paper</a> explaining the details of a project where we printed silver conductive ink on cotton. However, porous fabrics are more challenging to print on.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: What’s the typical print thickness with NOVA?</li><li id=""><strong id="">A</strong>: Approximately 20-25 µm after curing. Thickness can vary based on print settings, but typically metal inks exhibit some level of shrinkage after curing.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: How does silver ink compare to copper?</li><li id=""><strong id="">A</strong>: Although copper is cheaper as a raw material for traditional PCB manufacturing, its inks require additional processing to prevent oxidation. Silver is often the preferred material for additive electronics prototyping applications due to its high conductivity and chemical stability.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: Can silver conductive inks be used for RF applications?</li><li id=""><strong id="">A</strong>: Yes. Many <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=rf-circuits" id="">RF circuits</a> and <a href="https://www.voltera.io/use-cases/applications/printed-antennas" id="">antennas</a> have been successfully printed with silver conductive inks due to their high conductivity.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: Can you explain the process of the electroluminescent project? What was the dielectric used?</li><li id=""><strong id="">A</strong>: We have a white paper on the <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=electroluminescent-project" id="">electroluminescent project</a>, with inks used and the process documented. We used <a href="https://www.saralon.com/en/inks/dielectric-inks:saral-dielectric-600/" id="">Saralon Saral Dielectric 600 Dielectric Ink</a>.&nbsp;</li></ul><ul id=""><li id=""><strong id="">Q</strong>: Are silver inks flexible and stretchable?</li><li id=""><strong id="">A</strong>: It depends on the formulation. Inks like HPS U57B are designed for stretchable applications such as <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=wearable-sensors" id="">wearable sensors</a>.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: What soldering materials are recommended?</li><li id=""><strong id="">A</strong>: <a href="https://store.voltera.io/collections/materials?filter.p.m.custom.product_type=Solder+Paste" id="">Low-temperature solder pastes</a> such as tin-bismuth alloys are preferred to avoid damaging printed traces.</li></ul><ul id=""><li id=""><strong id="">Q</strong>: How can I use Voltera’s printing service to print my designs?</li><li id=""><strong id="">A</strong>: To get started, visit our <a href="https://www.voltera.io/products/printing-service?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=printing%20service" id="">printing service page</a> and tell us about your project requirements in the form.</li></ul><h2 id="">Additional resources</h2><p id="">Want to learn more about Voltera’s products and how they print silver conductive inks? Check out these resources:</p><ul id=""><li id="">Partner Highlight: <a href="https://blog.novacentrix.com/dispensing-systems-for-electronics-prototyping-from-voltera/" id="">Dispensing systems for electronics prototyping from Voltera</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=multilayer-blog" id="">Print Multilayer Flexible and Stretchable Circuits with NOVA</a></li><li id="">Videos: <a href="https://youtube.com/playlist?list=PLbZdiubRTqorowIyWJ2htVEbDG9y_XrZa&feature=shared" id="">Projects completed using NOVA</a></li><li id="">Videos: <a href="https://youtube.com/playlist?list=PLbZdiubRTqorfB-5XzLLe62Xbr9i-fqRc&feature=shared" id="">Projects completed using V-One</a></li></ul><p id="">Ready to talk about how our products and printing service can help you prototype? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-silver-conductive-inks&utm_content=book-a-meeting" id="">Book a meeting</a> to speak with a Voltera technical representative.</p>

Webinar Recap: Printing Electronics with Silver Conductive Inks

In this webinar, we explored how silver conductive inks are used in printed electronics, covering V-One and NOVA applications and material properties.

<p id=""><a href="https://www.voltera.io/use-cases/applications/bioelectronics?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=ai-powered-ingestible-sensor-monitoring-gut-health&utm_content=bioelectronics" id="">Bioelectronics</a> is where biology shakes hands with electronics, creating devices that “chat” with our bodies — think sensors that monitor glucose levels or implants that ease chronic pain. Prototyping these devices is like crafting a futuristic toolset: engineers, biologists, and product designers team up to turn bold ideas into devices that improve our quality of life.</p><p id="">Early prototypes often start as patchwork experiments: flexible circuits printed on skin-like materials, tiny sensors that “talk” to enzymes, or <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="">wearable patches</a> that track your heartbeat — all tested in labs (or sometimes garages). </p><p id="">When it comes to prototyping, a printing technology called <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=ai-powered-ingestible-sensor-monitoring-gut-health&utm_content=diw" id="">direct ink writing</a> helps researchers and developers iterate biosensor designs quickly by enabling design changes on-the-fly. Stretchable conductive inks and biocompatible materials ensure these devices conform seamlessly to and in the body. From <a href="https://www.nature.com/articles/s41467-022-33254-4" id="">smart contact lenses that measure eye pressure</a> to <a href="https://pmc.ncbi.nlm.nih.gov/articles/PMC6824398/" id="">neural implants restoring movement</a>, bioelectronics is reshaping healthcare. </p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67cf1ce3b65ec093aab2581d_ingestible-sensor-monitoring-gut-biomarker-electrodes.webp" loading="lazy" alt="Bioelectronics monitoring biomarkers" width="auto" height="auto" id=""></div><figcaption id="">Bioelectronics monitoring biomarkers</figcaption></figure><h2 id="">Printing a wearable sensor using NOVA</h2><p id="">Measuring gas concentrations in the gut offers important insights into our digestive health. By analyzing levels and locations of different gases like hydrogen and carbon dioxide, researchers can better understand the activity of the microbiome [1] and the complex interactions between gut bacteria and various health conditions, including imbalances linked to irritable bowel syndrome (IBS) or malabsorption [2].</p><p id="">Recently, researchers from the University of Southern California [3] used Voltera’s <a href="https://www.voltera.io/nova?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=ai-powered-ingestible-sensor-monitoring-gut-health&utm_content=nova" id="">NOVA materials dispensing system</a> to develop a wearable sensor that, together with an ingestible pill, maps gas concentrations in the gut with precision — all from the comfort of home.</p><p id=""><a href="https://www.cell.com/cell-reports-physical-science/fulltext/S2666-3864(24)00250-9" id="">Keep reading</a> to see how it works…</p><h2 id="">Conclusion</h2><p id="">Interested in more projects like this by our customers? Check out the following resources:</p><ul><li><a href="https://www.voltera.io/blog/printing-a-smart-resonator-to-track-meat-freshness">Printing a Smart Resonator to Track Meat Freshness</a></li><li><a href="https://www.voltera.io/blog/advancing-printed-sensors-rfid-tag-breath-monitoring">Advancing Printed Sensors: RFID Tag for Breath Monitoring</a></li></ul><p id="">Want to see how NOVA can support your biosensor and medtech projects? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=ai-powered-ingestible-sensor-monitoring-gut-health&utm_content=contact-us" id="">Contact us</a> for a demo. And if you're curious about future projects completed using NOVA, please <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=ai-powered-ingestible-sensor-monitoring-gut-health&utm_content=subscribe-newsletter" id="">subscribe to our newsletter</a>!&nbsp;</p><h2 id="">References</h2><p id="">[1] Chen, A. <a href="https://www.npr.org/sections/health-shots/2018/01/08/575944661/gut-check-gas-sniffing-capsule-charts-the-digestive-tract" id="">Gut Check: Gas-Sniffing Capsule Charts The Digestive Tract</a>. 2018.</p><p id="">[2] Dickson, I.&nbsp; (2018). Gas-sensing gut capsules. <em id="">Nature Reviews Gastroenterology &amp; Hepatology.</em> 15(131). <a href="https://doi.org/10.1038/nrgastro.2018.3" id="">https://doi.org/10.1038/nrgastro.2018.3</a>.&nbsp;</p><p id="">[3] Angsagan, A., et al. (2024). 3D gas mapping in the gut with AI-enabled ingestible and wearable electronics. <em id="">Cell Reports Physical Science</em>. 5(7). <a href="https://doi.org/10.1016/j.xcrp.2024.101990" id="">https://doi.org/10.1016/j.xcrp.2024.101990</a>.&nbsp;</p>

AI-Powered Ingestible Sensor for Monitoring Gut Health 

Researchers from the University of Southern California used Voltera NOVA to develop a wearable sensor for gut health monitoring.

AI-Powered Ingestible Sensor for Monitoring Gut Health

<p id="">In this webinar, our Technical Sales Lead, <a href="https://ca.linkedin.com/in/giovanni-obando-78512a7b" id="">Giovanni Obando</a>, walked attendees through the process of printing multilayer circuits using <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-multilayer-flexible-stretchable-circuits&utm_content=plan" id="">Plan</a>, the latest software feature of Voltera’s <a href="https://www.voltera.io/nova?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-multilayer-flexible-stretchable-circuits&utm_content=nova" id="">NOVA materials dispensing system</a>.&nbsp;</p><p id="">It included a live demonstration showcasing how Plan enables a new multilayer printing workflow, followed by a Q&amp;A session where attendees had the opportunity to gain deeper insights into compatible materials, print settings, and best practices for printing multilayer flexible circuits.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=_eH_6OMEIpI"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/_eH_6OMEIpI" title="Webinar: Printing Multilayer Flexible and Stretchable Circuits"></iframe></div></figure><h2 id="">Webinar highlights&nbsp;</h2><h3 id="">Overview of Plan and multilayer printing</h3><p id="">Key benefits of Plan include:</p><ul id=""><li id="">Efficient multilayer workflows: Users can stack up to four layers and visualize print sequences before execution.</li><li id="">Improved print job editing: Tool paths, probe targets, and traces can be adjusted for higher accuracy.</li><li id="">Height mapping optimization: Ensures precise ink dispensing on flexible and stretchable substrates.</li></ul><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67cf228a76acdb4eb871ea91_nova-printing-multilayer-flexible-stretchable-circuits.webp" loading="lazy" alt="Voltera’s NOVA materials dispensing system probing an existing printed layer to measure height changes before printing another layer on top" width="auto" height="auto" id=""></div><figcaption id="">NOVA probing the existing layer to account for height change</figcaption></figure><p id="">NOVA probing the existing layer to account for height change</p><h3 id="">Live demonstration</h3><p id="">Giovanni demonstrated the step-by-step process of printing multilayer designs with Plan:</p><ol id=""><li id="">Loading files: Importing Gerber files for a three-layer flexible circuit</li><li id="">Editing files: Adjusting dispense start/stop points, reordering layers, and refining print settings</li><li id="">Height mapping: Using the probe to measure layer height and prevent nozzle collisions</li><li id="">Executing the print job: Printing a conductive circuit on a flexible polyimide film</li></ol><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67cf227570523dc049ec648f_printing-multilayer-flexible-stretchable-circuits-inspection.webp" loading="lazy" alt="Inspecting print result using NOVA’s camera" width="auto" height="auto" id=""></div><figcaption id="">Inspecting print result using NOVA’s camera</figcaption></figure><p id="">Attendees saw first-hand how Plan simplifies multilayer printing and optimizes print quality and repeatability.</p><h3 id="">Key takeaways from Q&amp;A&nbsp;</h3><p id="">During the Q&amp;A, attendees asked insightful questions about multilayer printing, material compatibility, and best practices. Some key takeaways included:</p><ul id=""><li id="">Flexible and stretchable materials: NOVA supports most screen-printable inks, including <a href="https://store.voltera.io/products/aci-ss1109-2ml-cartridge" id="">stretchable silver</a> and <a href="https://store.voltera.io/products/aci-sc1502-2ml-cartridge" id="">carbon inks</a>, for applications such as <a href="https://www.voltera.io/use-cases/applications/wearables" id="">wearables</a>, <a href="https://www.voltera.io/use-cases/applications/printed-antennas" id="">printed antennas</a>, and <a href="https://www.voltera.io/use-cases/applications/bioelectronics" id="">bioelectronics</a>.</li><li id="">Substrate compatibility: NOVA can print on soft substrates such as fabric, flexible substrates like <a href="https://store.voltera.io/products/polyimide-5-sheets" id="">polyimide (PI)</a> and <a href="https://store.voltera.io/products/pet-5-sheets" id="">polyethylene terephthalate (PET)</a>, as well as rigid substrates like <a href="https://store.voltera.io/search?q=fr1&options%5Bprefix%5D=last&filter.p.m.custom.product_type=Substrates&sort_by=relevance" id="">FR1</a> and <a href="https://store.voltera.io/search?q=fr4&options%5Bprefix%5D=last&filter.p.m.custom.product_type=Substrates&sort_by=relevance" id="">FR4</a>.</li><li id="">Ink selection and curing: The choice of ink depends on conductivity, adhesion, and flexibility, with thermal curing required after each layer.</li><li id="">Alignment and fiducials: We recommend using fiducial markers for precise layer alignment.</li><li id="">Offline use of Plan: An internet connection is required to enable cloud access. Stay tuned for future updates to this functionality.</li></ul><h2 id="">Additional resources</h2><p id="">Want to explore multilayer projects completed with NOVA? Check out these helpful resources:</p><ul id=""><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet" id="">Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet" id="">Printing Electroluminescent Ink on Paper and PET</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="">Printing a Flexible PCB with Silver Ink on PET</a></li></ul><p id="">Ready to print multilayer flexible circuits? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-multilayer-flexible-stretchable-circuits&utm_content=book-a-meeting" id="">Book a meeting</a> to learn more about NOVA, or check out our <a href="https://www.voltera.io/printing-service?srsltid=AfmBOoqLpYy3QISNkxU4dFea2CKBaCVGlCC9rwZvLMKEGiLz8xovhQBr" id="">printing service</a>.</p>

Webinar Recap: Printing Multilayer Flexible And Stretchable Circuits

This webinar explored multilayer flexible circuit printing using Plan, NOVA’s latest software feature, demonstrating layer stacking and trace editing.

<p id="">In the ever-evolving landscape of electronics manufacturing, terminology often carries hidden histories and technical nuances that shape industry practices. Two such terms — printed wiring board (PWB) and printed circuit board (PCB) — are often used interchangeably, but they represent distinct phases in the evolution of electronics.&nbsp;</p><p id="">While modern usage increasingly favors PCB as the catch-all term, comparing the difference between PCBs and PWBs in electronics reveals a fascinating journey from rudimentary electrical interconnections to today’s sophisticated, multi-functional electronic systems.</p><h2 id="">PWB and PCB: A historical and functional comparison</h2><p id="">The terms PWB and PCB both describe non-conductive materials with conductive pathways, but they carry different historical and functional implications. <a href="https://www.mclpcb.com/blog/history-of-pcbs/#history" target="_blank" id="">Historically</a>, PWB (printed wiring board) referred to boards with simple etched traces on basic substrates like phenolic paper, focusing solely on wiring connections. These were foundational in early electronics, such as industrial control systems, where basic interconnections were all that was required.</p><p id="">In contrast, the term printed circuit board emerged as the modern label for boards with more advanced materials, such as FR4 fiberglass, and designs that support features like multilayer routing, plated through-holes, and high-density interconnects. According to <a href="https://www.wevolver.com/article/pwb-vs-pcb" target="_blank" id="">Wevolver</a>, PCBs support advanced functionalities like multilayer board designs, signal integrity management, and thermal regulation, making them indispensable in modern electronic devices like smartphones and automotive systems.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67ae5257289ed7626e788097_pwb-pcb-additive-electronics-fr4-boards.webp" loading="lazy" alt="Stack of Voltera FR4 substrates for printed circuit board prototyping." width="auto" height="auto" id=""></div><figcaption id="">FR4 substrates</figcaption></figure><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/67ae529b5e0e99ea60df0666_Blog_PWB%20and%20PCB%20table%201.txt[/script]</p><p id="">Even though the term PWB is still used in some regions — such as Japan — <a href="https://absolutepcbassembly.com/pwb-vs-pcb/" target="_blank" id="">to avoid confusion with polychlorinated biphenyls</a> (toxic chemicals), the term PCB is now the global standard for unpopulated circuit boards.</p><h2 id="">From bare boards to functional electronics: PCBA and packaging&nbsp;</h2><p id="">The key difference lies not between PWB and PCB, but between bare boards (PWB/PCB) and assembled boards (PCBAs). While PWBs and PCBs serve as the foundation of electronic circuits, they remain non-functional until there are electrical components soldered onto them.</p><p id="">For example, the motherboard in a smartphone begins as a multilayer PCB substrate material. During <a href="https://www.wevolver.com/article/pcb-vs-pcba" target="_blank" id="">PCB assembly</a>, surface mount technology (SMT) streamlines the placement of tiny micro-components such as resistors, capacitors, and integrated circuits (ICs) onto the board’s surface. Reflow soldering then secures these essential components, bringing the PCB to life as a functional electronic system.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67ae52dcfd5722c02c75644e_pwb-additive-electronics-voltera-pcba-reflow.webp" loading="lazy" alt="Decimal counter PCB assembly with seven-segment displays and surface-mount components during reflow on Voltera V-One." width="auto" height="auto" id=""></div><figcaption id="">A decimal counter printed circuit board assembly being reflowed on V-One</figcaption></figure><p id="">Beyond printed circuit assembly, advanced electronics packaging has further transformed how circuit boards function. Technologies like <a href="https://ats.net/en/technologies/ecp-technology/" target="_blank" id="">embedded component packaging</a> (ECP) integrate passive components directly into PCB layers, reducing size while improving performance. Similarly, <a href="https://www.protoexpress.com/kb/enig/" target="_blank" id="">electroless nickel immersion gold</a> (ENIG) finishes enhance electrical signal reliability and corrosion resistance, making PCBs more durable in high-performance applications like 5G networks, aerospace systems, and IoT devices.</p><p id="">The journey from simple PWBs to highly integrated PCBs and advanced packaging reflects how electronics have evolved from basic electrical connections to intelligent, high-density systems that power the intelligent era.</p><h2 id="">Rethinking the future of PCB fabrication with <strong id="">additive manufacturing processes</strong></h2><p id="">As electronics demand greater customization, miniaturization, and sustainability, additive manufacturing is redefining PCB fabrication. One such technology is <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct Ink writing</a> (DIW). Unlike traditional subtractive etching, DIW deposits conductive ink, dielectric ink, or other functional inks and pastes directly onto PCB substrates. This method <a href="https://www.sciencedirect.com/science/article/pii/S2542435118301302" target="_blank" id="">significantly reduces material waste</a> and enables rapid prototyping of <a href="https://www.sciencedirect.com/science/article/pii/S0001868624000186" target="_blank" id="">complex geometries</a>, such as stretchable surfaces for wearable devices.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67ae52f94df649055d04dace_pwb-pcb-additive-electronics-conductive-traces.webp" loading="lazy" alt="High-precision conductive traces printed on a PCB with the Voltera V-One, featuring a microscope close-up showing trace width of ~202 µm." width="auto" height="auto" id=""></div><figcaption id="">High precision conductive tracks printed by V-One</figcaption></figure><p id="">Even PCBA is evolving through additive techniques. Traditional PCBA relies on stencil printing, where a metal stencil is used to apply solder paste onto PCB pads before placing and connecting electronic components via reflow soldering. As such, it has several limitations, including the need for custom stencils for each printed board design, difficulty in handling fine-pitch components, and inefficiencies in prototyping or low-volume runs. DIW platforms such as Voltera’s <a href="https://www.voltera.io/v-one" id="">V-One PCB printer</a> and <a href="https://www.voltera.io/nova" id="">NOVA materials dispensing system</a> can directly print solder paste onto PCB substrates, reducing the need for traditional stencils.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/673b855a8af066bbb936caec_flexible-pcb-solder-dispensing.webp" loading="lazy" alt="NOVA dispensing solder paste precisely onto pads of a flexible LED roulette circuit" width="auto" height="auto" id=""></div><figcaption id="">NOVA dispensing solder paste exactly where needed</figcaption></figure><p id="">Researchers and developers have also explored <a href="https://www.ipc.org/system/files/technical_resource/E15&S28_01.pdf" target="_blank" id="">embedding components during fabrication</a> — a potential step toward merging fabrication and assembly into a single, seamless electronics manufacturing process. This shift could blur the lines between PCB fabrication and PCBA, leading to entirely new ways of designing and manufacturing electronics.</p><h2 id="">Conclusion</h2><p id="">While the terms PWB and PCB reflect historical nuances in board fabrication, they both describe non-functional substrates — until PCBA brings them to life. But the shift from PWB to PCB wasn’t just about terminology. It reflected a major leap in how electronics are designed and manufactured, paving the way for more complex, high-performance systems.</p><p id="">Now, with the rise of PCB additive manufacturing, we are well on our way to another transformation — one that could merge PCB fabrication with PCB assembly. The fascinating journey of electronics is far from over. As we rethink legacy technologies and embrace new PCB manufacturing methods, the future of circuit boards will continue to evolve in ways we have yet to imagine, but one thing is for sure: the future is being built layer by layer.</p><p id="">Want to see our additive PCB prototyping projects? Check out these resources:</p><ul id=""><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-control-board-line-following-robot-silver-ink-fr1" id="">Printing a Control Board for a Line Following Robot with Silver Ink on FR1</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/dispensing-solder-paste-factory-fabricated-pcbs" id="">Dispensing Solder Paste on Factory Fabricated PCBs</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet" id="">Printing a Flexible PCB with Silver Ink on PET</a></li></ul><p id="">And if you're curious about the latest Voltera content, don’t forget to <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a?__hstc=13863464.a6e861abd69863d5e355c083710f6ae2.1708615212577.1737667977279.1737694163529.597&__hssc=13863464.2.1737694163529&__hsfp=3011104808" id="">subscribe to our newsletter</a>!</p><h2 id=""><strong id="">Frequently Asked Questions</strong></h2><h3 id="">Can I create electronic prototypes using a printed wiring board (PWB) instead of a printed circuit board (PCB)?</h3><p id="">Yes, if the design is simple. “PWB” historically meant a basic wiring board with conductive traces; for multiple layers, tighter spacing, and reliability across the entire board, modern PCBs are a better fit for most prototypes.</p><h3 id="">What’s the difference between PWB, PCB, and PCBA?</h3><p id="">PWB is the older term tied to simpler, wiring-focused boards; PCB is the modern term for boards that support features like multiple layers and plated through-holes. PCBA is the board after attaching components, which is the version used in products.</p><h3 id="">Are additive manufacturing methods suited to consumer devices?</h3><p id="">Additive methods shine for R&amp;D, fast iteration, and short pilot runs. For high volumes in consumer electronics, mass production still favors etched laminates with copper traces due to cost and throughput.</p><h3 id="">Does additive PCB fabrication change the component mounting process?</h3><p id="">You still apply solder to pads, place components, and reflow to form joints. What changes is the step before mounting: additive tools can dispense solder paste directly onto pads (including on prefabricated boards), enabling stencil-free assembly on early spins. That reduces setup time and can lower manufacturing costs while you iterate.</p><h2 id=""><strong id="">Check out our Customer Stories</strong></h2><p id="">Take a closer look at what our customers are doing in the electronics industry.</p><p id="">[<a href="https://www.voltera.io/customer-stories" id="">Visit Customer Stories</a>]</p>

PWB vs. PCB in the Age of Additive Electronics

Ever wondered what a PWB is? This blog compares PWBs and PCBs while exploring how PCB manufacturing technologies adapted to meet the demands of a new age.

<p id="">Today, Voltera is announcing NOVA software update v1.16, which unlocks an exciting beta feature — multilayer printing and print job editing. This feature is in direct response to requests from NOVA users who are frequently printing multilayer or multi-material designs.</p><h2 id="">What is Plan?</h2><p id="">To understand Plan, it’s important to first understand NOVA. NOVA uses <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink writing (DIW) technology</a> to print circuits on soft, stretchable, and conformable substrates. Its free software is what enables users to interact with NOVA. You can choose different workflows to perform different operations:&nbsp;</p><ul id=""><li id="">Dispense: Dispense a selected material on a selected substrate.</li><li id="">Materials: Browse, create, modify, and delete material profiles.</li><li id="">Calibrate: Figure out print settings for a new material or nozzle.</li></ul><p id="">And now, we are adding another tile — Plan.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/678ab14a3e8d68cba69cd1e5_676074a59d951f67841cfb69_printing-multilayer-circuits-workflows-nova-software.webp" loading="lazy" alt="Main menu of the Voltera NOVA software showing workflow options: Dispense, Materials, Calibrate, and Plan." width="auto" height="auto" id=""></div><figcaption id="">Workflows in the NOVA software</figcaption></figure><p id="">Here is how Plan makes your printing process smoother:</p><ul id=""><li id="">Multilayer printing<ul id=""><li id="">View and set up complete multilayer designs in one step.</li><li id="">Identify print errors before dispensing, ensuring repeatable results.</li><li id="">Generate smart probe points, taking into account subtle height changes each subsequent layer creates.</li><li id="">Create a detailed height map while minimizing height mapping time.</li></ul></li><li id="">Print job editing<ul id=""><li id="">Easily visualize design features such as toolpaths and probe points.</li><li id="">Adjust the print order of design features to achieve repeatable results.</li><li id="">Delete unwanted design features to simplify the print process.</li><li id="">Save print jobs with the same settings, allowing for easy reprints with consistent results.</li></ul></li></ul><p id="">Watch this video to see it in action:</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=i6wUTKv6mYs"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/i6wUTKv6mYs" title="Print Multilayer and Multi-Material Flexible Circuits Voltera NOVA's Plan Feature"></iframe></div></figure><p id="">If you're curious about NOVA’s specifications and how they tie into printing multilayer designs, here’s what you need to know:</p><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/677816f8e0a27d5ae5435dc1_Blog_Plan%20Feature%20Launch%20table%201.txt[/script]</p><p id="">* Designs with more than 4 stack-up layers are achievable but depend on a number of factors. For more information, contact Support at support@voltera.io.</p><h2 id="">What you can do with Plan</h2><p id="">Now that we’ve covered Plan’s features, let’s take a closer look at the multilayer flexible circuits we’ve completed.</p><h3 id="">Flexible membrane keyboard</h3><p id="">This flexible membrane keyboard consists of a control board and a 10-number keypad printed on PET using ACI Materials’ silver ink, insulating ink, and T4 solder paste. <a href="https://www.voltera.io/application-whitepapers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet" id="">Read the white paper</a> to learn more.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/678ab14a3e8d68cba69cd1e8_67607970589894e4655e978b_printing-multilayer-circuits-flexible-membrane-keyboard.webp" loading="lazy" alt="Flexible membrane keyboard circuit printed on PET, featuring dome switches and conductive traces, connected to a rigid PCB." width="auto" height="auto" id=""></div><figcaption id="">Flexible membrane keyboard on PET</figcaption></figure><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/677816f84632617df2fe99fc_3f42e6b7a983525e5716598fbbe5e35f_Blog_Plan%20Feature%20Launch%20table%202.txt[/script]</p><h3 id="">Electroluminescent circuit</h3><p id="">This is an electroluminescent display printed on PET and paper using Saralon’s conductive inks, phosphor ink, and dielectric ink. <a href="https://www.voltera.io/application-whitepapers/printing-electroluminescent-ink-paper-pet" id="">Read the white paper</a> to learn more.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/678ab14a3e8d68cba69cd1cb_67607a373950efc6642b2f8d_printing-multilayer-circuits-electroluminescent-display-paper.webp" loading="lazy" alt="Electroluminescent display of Voltera’s logo printed on paper, glowing in blue and connected with conductive traces." width="auto" height="auto" id=""></div><figcaption id="">Electroluminescent circuit on paper</figcaption></figure><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/677816f8750749270399ea44_Blog_Plan%20Feature%20Launch%20table%203.txt[/script]</p><h3 id="">Flexible LED roulette circuit</h3><p id="">For this project, we took a LED roulette circuit we had previously developed as a rigid PCB on FR4, and then converted it for printing on PET.<a href="https://www.voltera.io/application-whitepapers/printing-flexible-pcb-silver-ink-pet" id=""> Read the white paper</a> to learn more.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/678ab14a3e8d68cba69cd1ce_67607ad020d26aa924f9e294_printing-multilayer-circuits-flexible-led-roulette.webp" loading="lazy" alt="Flexible LED roulette circuit printed on PET, with surface-mounted components and a lit blue LED light up, being folded by hand." width="auto" height="auto" id=""></div><figcaption id="">Flexible LED roulette circuit on PET</figcaption></figure><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/6778177c30b815aec910f276_5b6653749db506e40a620487d2ac06fb_Blog_Plan%20Feature%20Launch%20table%204.txt[/script]</p><p id="">The possibilities are endless. Explore more multilayer projects by checking out our <a href="https://www.voltera.io/use-cases/white-papers" id="">other white papers</a>.</p><h2 id="">What makes Plan different?</h2><p id="">Unlike other software solutions for multilayer electronics printing, Plan is designed to be beginner-friendly, focusing on ease of use and efficient printing. Nick Levinski, an MASc student in Mechanical and Mechatronics Engineering at the University of Waterloo, shared his experience after using Plan to prototype flexible and stretchable sensors for <a href="https://www.voltera.io/applications/wearables" id="">wearable electronics</a>:</p><p id="">“The plan feature has definitely simplified a lot of my regular workflows. For my research, a lot of it involves developing sensors. With the Plan feature multilayer deposition, I can now relax a lot of constraints by separating different sensor elements, traces, or components to different layers and removing toolpaths that I don’t want.”</p><p id="">Watch to see how Plan helps Nick print multilayer sensors for soft robotics:</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/tG3YzCNbIs0"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/tG3YzCNbIs0" title="Voltera NOVA | Introducing Plan, NOVA's New Feature for Printing Multilayer Flexible Circuits"></iframe></div></figure><p id="">‍</p><h2 id="">What’s next?</h2><p id="">Now that you’ve seen how Plan works and the possibilities it unlocks, here’s how to get started:</p><h3 id="">If you have NOVA</h3><p id="">Update the software:</p><ol id=""><li id="">Connect your NOVA to your computer and the internet.&nbsp;</li><li id="">Visit <a href="http://www.myvoltera.io" id="">www.myvoltera.io</a> and log into your account.&nbsp;</li><li id="">The NOVA software update (v1.16) will download automatically. Once the update is complete, the <strong id="">Plan</strong> tile will appear as a new workflow on your home screen.&nbsp;</li></ol><h3 id="">Offline users</h3><p id="">Offline use of Plan is not available in this release, and an internet connection is required. Stay tuned for <a href="https://docs.voltera.io/nova/software/release-notes" id="">future updates</a> to enable offline functionality.</p><h3 id="">Don’t have a NOVA yet?&nbsp;</h3><p id="">If you’re printing multilayer flexible or stretchable circuits and don’t have a NOVA yet, contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Plan%2FMultilayer%20Launch&utm_source=website&utm_medium=plan-launch-blog&utm_term=printing-multilayer-circuits-nova-plan-feature&utm_content=book-a-meeting" id="">book a demonstration </a>with our technical team.&nbsp;&nbsp;In the meantime, check out these resources for additional information:</p><ul id=""><li id=""><a href="https://docs.voltera.io/nova/plan/designing-multi-layer-artworks" id="">Designing Multi-Layer Artworks</a></li><li id=""><a href="https://docs.voltera.io/nova/learn-more/working-with-custom-inks" id="">Working with Custom Inks</a></li><li id=""><a href="https://www.wevolver.com/article/electronics-that-bend-the-rules-the-benefit-of-flexible-multilayer-designs" target="_blank" id="">Electronics That Bend the Rules: The Benefit of Flexible Multilayer Designs</a></li></ul>

Print Multilayer Flexible and Stretchable Circuits with NOVA

Are you printing multilayer flexible, stretchable, and conformable electronics? Check out how NOVA’s new Plan feature makes multilayer printing easy.

<p id="">Sensors are everywhere — these clever electronic devices detect and respond to changes in the environment, turning physical, chemical, or biological information into measurable signals. From smart watches to medical devices, they’re shaping the future of technology.</p><p id="">And that future is growing fast. According to <a href="https://www.idtechex.com/en/research-report/printed-and-flexible-sensors-2024-2034-technologies-players-markets/993" target="_blank" id="">IDTechEx</a>, the printed sensor market was valued at USD $421 million in 2024 and is expected to grow at 8.6% annually through 2034. One area driving this growth is biosensors, which are gaining momentum thanks to the rising prevalence of chronic diseases like diabetes and cardiovascular disorders.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/679a41db36a8495ec54a8a08_679a40f51b873211fa8a8fba_advancing-printed-sensors-idtechex-market-report.webp" loading="lazy" alt="Two donut charts comparing global printed sensor annual revenue in 2024 and 2034, including temperature, photodetectors, capacitive, wearable electrodes, strain, gas, and piezoelectric sensors" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.idtechex.com/en/research-report/printed-and-flexible-sensors-2024-2034-technologies-players-markets/993" target="_blank" id="">Global sensor market size, 2024 – 2034</a></figcaption></figure><p id="">At Voltera, we’re right in the middle of this exciting space, pushing the boundaries of printed electronics. Biosensors are a particular focus for us, and we’ve been working on some exciting projects, including:</p><ul id=""><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="">Gold electrocardiogram (ECG) electrodes</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper" id="">Ultra-high frequency (UHF) radio frequency identification (RFID) tag</a></li><li id=""><a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" id="">Stretchable strain gauges</a></li></ul><p id="">But it’s not just us driving innovation. Our <a href="https://www.voltera.io/use-cases/customer-stories" id="">customers</a> are constantly inspiring us with their work. For example, researchers from Universitat Politècnica de Catalunya in Spain recently developed a biosensor using our <a href="https://www.voltera.io/nova" id="">NOVA materials dispensing system</a> and published their findings in Electronics [1]. It’s research like this that keeps us excited about the future of sensor technology.</p><h2 id="">Developing a stretchable respiration sensor</h2><p id="">The research team aimed to develop a wearable sensor to track inspiration (the process of inhaling air into the lungs) and expiration (the process of exhaling air out of the lungs) cycles. The sensor consists of three key components:</p><ul id=""><li id="">A UHF RFID tag</li><li id="">A copper strip</li><li id="">An adhesive belt</li></ul><h3 id="">Sensor design&nbsp;</h3><p id="">The RFID tag features two non-symmetrical meander dipoles with a central loop that connects to the <a href="https://www.murata.com/~/media/webrenewal/products/rfid/rfid/uhf/uhf-smd/media-datasheets/uhf%20rfid%20tag%20lxms21acnp-184%20datasheet%20rev1_1_181130.ashx?la=en-us" target="_blank" id="">UHF RFID chip</a>. This asymmetric design enhances sensitivity to displacement variations (Δ𝑑), making it well-suited for respiration monitoring.&nbsp;</p><p id="">During testing, the sensor was integrated into an elastic belt and worn around the abdominal region, allowing it to detect breathing by monitoring changes in the relative position of the copper strip and RFID tag during respiration.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/679a41db36a8495ec54a8a13_679a414d2ac50f8784179ce7_advancing-printed-sensors-design-diagram-sensor.webp" loading="lazy" alt="Two-part figure showing an RFID-based stretch sensor. (a) Schematic diagram of an elastic belt with adhesive tape, a copper strip, and an RFID tag attached, marked with a 50 mm scale. (b) Photograph of the actual prototype, with a copper strip and RFID tag fixed to a fabric belt using adhesive tape" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.mdpi.com/2079-9292/14/2/262" target="_blank" id="">Diagram and photograph of the sensor</a></figcaption></figure><h3 id="">Printing the RFID tag</h3><p id="">The RFID tag was printed using NOVA with <a href="https://store.voltera.io/products/aci-fs0142-2ml-cartridge?" id="">ACI FS0142A silver conductive ink</a> on a <a href="https://store.voltera.io/products/polyimide-5-sheets" id="">0.2 mm thick Kapton (polyimide) substrate</a>, chosen for its flexibility and durability.&nbsp;</p><p id="">The NOVA software, which supports Gerber files from any ECAD software, automatically generated toolpaths to dispense the conductive ink onto the designated area. After printing, the tag was cured at 40°C for 20 minutes to ensure optimal electrical performance while maintaining flexibility for wearable applications.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/679a41db36a8495ec54a8a10_679a417e8e39516d11580e57_advancing-printed-sensors-fabrication-process-rfid.webp" loading="lazy" alt="The fabrication process of the printed RFID tag. On the left, the antenna design is displayed in NOVA software, then shown as a printed tag with an attached chip. On the right, a Voltera NOVA material dispensing system is pictured printing the design onto a substrate." width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.mdpi.com/2079-9292/14/2/262" target="_blank" id="">The printing process</a></figcaption></figure><h3 id="">Sensor operation</h3><p id="">The sensor functions through mutual inductive coupling between the printed RFID tag and the copper strip. Changes in displacement (Δ𝑑) during respiration modulate the tag impedance, which affects power transmission efficiency, and the transmission coefficient, which influences the backscattered signal strength received by the reader.</p><h3 id="">Results</h3><p id="">Experimental results demonstrated a 9 dB reduction in the received signal strength indicator (RSSI) and a 2.3 m decrease in read range within the first 12 mm of displacement. In addition, the sensor successfully tracked respiratory cycles, showing an approximate 5 dB variation between inspiration and expiration phases when worn around the abdominal region.</p><h2 id="">Conclusion</h2><p id="">The study validated the sensor’s potential for remote patient monitoring as a cost-effective, battery-free solution. Its lightweight, flexible design enables seamless integration into <a href="https://www.voltera.io/use-cases/applications/wearables" id="">wearable applications</a>, providing real-time respiratory tracking without bulky or invasive equipment.</p><p id="">Interested in more projects like this by our customers? Check out the following resources:</p><ul id=""><li id=""><a href="https://www.voltera.io/blog/printing-a-smart-resonator-to-track-meat-freshness" id="">Printing a Smart Resonator to Track Meat Freshness</a></li><li><a href="https://www.voltera.io/blog/ai-powered-ingestible-sensor-monitoring-gut-health">AI-Powered Ingestible Sensor for Monitoring Gut Health</a></li></ul><p id="">Want to see how NOVA can support your next big idea? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=advancing-printed-sensors-rfid-tag-breath-monitoring&utm_content=book-a-meeting" id="">Contact us</a> today! And if you're curious about this, or other projects completed using NOVA, don’t forget to <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a?__hstc=13863464.a6e861abd69863d5e355c083710f6ae2.1708615212577.1737667977279.1737694163529.597&__hssc=13863464.2.1737694163529&__hsfp=3011104808" id="">subscribe to our newsletter.</a>&nbsp;</p><h2 id="">Reference</h2><p id="">[1] Hussain, T., Gil, I., &amp; Fernández-García, R. (2025). Wearable Displacement Sensor Using Inductive Coupling of Printed RFID Tag with Metallic Strip. <em id="">Electronics</em>, 14(2), 262. <a href="https://doi.org/10.3390/electronics14020262" target="_blank" id="">https://doi.org/10.3390/electronics14020262</a>.&nbsp;</p>

Advancing Printed Sensors: RFID Tag for Breath Monitoring

Researchers used NOVA to print a ultra-high frequency RFID tag for a stretchable respiration sensor that enables real-time, non-invasive breath monitoring.

<p id="">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="">What are flexible hybrid electronics?</h2><p id="">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" id="">new applications</a> in fields such as healthcare, consumer electronics, automotive, and beyond.</p><p id="">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" id="">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 id="">Key components of flexible hybrid electronics</h2><p id="">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 id="">Substrates for FHEs</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67575ad97d5c5c3dd312bc32_bendable-pet-substrate-flexible-hybrid-electronics.webp" loading="lazy" alt=""></div><figcaption><a href="https://www.voltera.io/use-cases/white-papers/printing-magnesium-zinc-battery-saral-inks-pet">Flexible battery</a> printed on PET substrate</figcaption></figure><p id="">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&_fid=65f88ddf8&_ss=c" id="">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&_fid=65f88ddf8&_ss=c" id="">thermoplastic polyurethane (TPU)</a>, <a href="https://store.voltera.io/products/polyimide-5-sheets?_pos=8&_fid=65f88ddf8&_ss=c" id="">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" id="">BEYOLEX</a>, and even novel substrates can offer different advantages, like biocompatibility or increased stretchability.&nbsp;</p><p id="">Some common substrate suppliers include (but are not limited to):</p><ul id=""><li id=""><a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials" target="_blank" id="">Panasonic</a></li><li id=""><a href="https://normandy-coating.com/en/" target="_blank" id="">Normandy Coating</a></li><li id=""><a href="https://www.dupont.com/electronics-industrial/printed-circuit-boards.html" target="_blank" id="">Dupont</a></li><li id=""><a href="https://polyonics.com/Resources/about-our-products.php#" target="_blank" id="">Polyonics</a></li></ul><h3 id="">Conductors and interconnects for FHEs</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67575b0cbddec4287e182d8d_printing-conductive-copper-ink-flexible-hybrid-electronics.webp" loading="lazy" alt="Close-up of a direct ink writing printer, NOVA materials dispensing system, printing nano copper ink onto paper in a serpentine pattern to fabricate an RFID tag antenna"></div><figcaption>Printing nano copper ink on paper to make an <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper">RFID tag</a></figcaption></figure><p id="">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" id="">inkjet printing</a>, and aerosol printing. <a href="https://www.voltera.io/blog/screen-printing-direct-ink-writing-printed-electronics" id="">Direct ink writing</a>, in particular, ensures that ink is only applied where it is needed which eliminates unnecessary material waste.&nbsp;</p><p id="">Some common ink suppliers for FHE include (but are not limited to):</p><ul id=""><li id=""><a href="https://www.acimaterials.com/products/" target="_blank" id="">ACI Materials&nbsp;</a></li><li id=""><a href="https://www.celanese.com/" target="_blank" id="">Celanese</a></li><li id=""><a href="https://www.copprint.com/products/" target="_blank" id="">Copprint</a></li><li id=""><a href="https://www.creativematerials.com/products" target="_blank" id="">Creative Materials</a></li><li id=""><a href="https://www.elantas.com/europe/products/printed-electronics/products.html" target="_blank" id="">Elantas</a></li><li id=""><a href="https://www.henkel-adhesives.com/ca/en/products/industrial-coatings/inks-coatings.html" target="_blank" id="">Henkel</a></li><li id=""><a href="https://www.heraeus-group.com/en/heraeus-businesses/#electronics" target="_blank" id="">Heraeus</a></li><li id=""><a href="https://novacentrix.com" target="_blank" id="">Novacentrix</a></li><li id=""><a href="https://vfp-ink-technologies.com/functionnal-decorative-inks-varnishes/" target="_blank" id="">VFP</a></li></ul><h3 id="">Components for FHEs</h3><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/675759a4c441da78918b7d60_flexible-hybrid-electronics-printed-pcb.webp" loading="lazy" alt=" Flexible printed circuit board populated with components encapsulated by an epoxy resin being bent"></div><figcaption>A <a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet">flexible printed LED roulette circuit </a></figcaption></figure><p id="">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" id="">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 id="">Flexible hybrid electronics vs printed electronics vs flexible printed circuit boards</h2><p id="">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" id="">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 id=""><a href="https://www.idtechex.com/en/research-article/flexible-hybrid-electronics-future-of-flexible-printed-circuit-boards/20603" target="_blank" id="">Comparison of FHE vs PE vs FPCB</a></h3><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/67586618b3c3ed4a68f1dd6a_FHE%20blog%20table.txt[/script]</p><h2 id="">Future outlook for flexible hybrid electronics</h2><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67575b836033c6402dc43a27_gold-ecg-electrode-bioelectronics-future.webp" loading="lazy" alt="Close-up of a printed biocompatible ECG electrode adhered to the skin with medical tape. The flexible gold circuit connects to a snap connector for monitoring."></div><figcaption>A <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">printed biocompatible ECG electrode</a></figcaption></figure><p id="">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" id=""> IDTechEx</a>, the flexible hybrid electronics market is projected to reach $1.8 billion USD by 2034.&nbsp;</p><p id="">The main industries positioned for growth in the flexible hybrid electronics market are:</p><ul id=""><li id=""><a href="https://www.voltera.io/applications/bioelectronics" id="">Bioelectronics</a>: FHEs enable flexible, biocompatible devices like biosensors, electrodes, and wearable health monitors, improving personalized medicine and real-time patient care.</li><li id=""><a href="https://www.voltera.io/applications/wearables" id="">Wearables</a>: FHEs make smart devices, fitness trackers, and e-textiles lighter, more comfortable, and more durable.</li><li id=""><a href="https://www.voltera.io/applications/printed-batteries" id="">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 id=""><a href="https://www.voltera.io/applications/printed-antennas" id="">Antennas</a>: FHE-based antennas enable high-performance, bendable communication systems for 5G, IoT devices, and compact wearables.</li></ul><p id="">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 id="">Take a look at some of our in-house FHE projects:</p><ul id=""><li id=""><a href="https://www.voltera.io/application-whitepapers/printing-electroluminescent-ink-paper-pet" id="">Printing Electroluminescent Ink on Paper and PET</a></li><li id=""><a href="https://www.voltera.io/application-whitepapers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet" id="">Printing a Flexible Membrane Keyboard with Conductive Silver Ink and Dielectric Ink on PET</a></li></ul><p id="">Want the latest news in printed electronics? <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a" id="">Subscribe to our newsletter</a>. Meanwhile, if you have questions about your PCB printing needs, please contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting" id="">book a meeting</a>.</p>

What are Flexible Hybrid Electronics (FHE)?

A guide to flexible hybrid electronics, their key components, future outlook, and a comparison with printed electronics and flexible printed circuit boards.

What are Flexible Hybrid Electronics? | Voltera

<p id="">In a recent webinar, our Support Lead, Nathan Shinkar, demonstrated the printing process of a seven-segment display (99 decimal counter) using our PCB printer, <a href="https://www.voltera.io/v-one" id="">V-One</a>.</p><p id="">This project, designed by <a href="http://itiz.co.kr/vone/" id="">ITIZ</a>, our authorized reseller in South Korea, aims to teach a fundamental aspect of electrical engineering: PCB development. It includes circuits for power regulation, pulse generation, and digital counting.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=h5EiL5QOOO0"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/h5EiL5QOOO0" title="Webinar: Printing PCBs for Hands-On Learning"></iframe></div></figure><h2 id="">Webinar highlights&nbsp;</h2><h3 id="">Overview of the software and the print workflow</h3><p id="">Nathan began the webinar with an overview of the V-One software and one of its four workflows: <strong id="">Print</strong>. Before the live demonstration, he walked through several preparation steps, including:</p><ol id=""><li id="">Loading the Gerber file</li><li id="">Cleaning the X and Z positioner</li><li id="">Clamping the FR4 board</li><li id="">Mounting the probe</li></ol><h3 id="">Project overview</h3><p id="">While the Smart Probe created a height map of the FR4 board, Nathan showcased the final product and provided an overview of the project. It features three interconnected PCBs:</p><ul id=""><li id="">Voltage regulator board<ul id=""><li id="">Converts a 9V input into a steady 5V output, allowing students to compare linear and switching regulators.</li></ul></li><li id="">Pulse generator board<ul id=""><li id="">Uses a 555 timer chip to produce pulse signals, which are sent to the final board to drive the counting circuit.</li></ul></li><li id="">Digital counter board<ul id=""><li id="">Counts from 0 to 99 using seven-segment displays, with adjustable speed control and a reset button.</li></ul></li></ul><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67782cbaeec7a93878566945_67782c5c7f638c68dc6cca50_webinar-recap-printing-pcbs-final-product.webp" loading="lazy" alt="__wf_reserved_inherit" width="auto" height="auto" id=""></div><figcaption id="">Final product of the decimal counter</figcaption></figure><h3 id="">Live demonstration and Q&amp;A&nbsp;</h3><p id="">We demonstrated the printing process for the digital counter board. After calibrating the ink, V-One printed conductive traces on the FR4 board. The process took approximately 15 minutes, during which Nathan addressed attendee questions. Here are a few highlights:</p><ul id=""><li id="">Can V-One print multiple layers?some text<ul id=""><li id="">V-One supports two-sided PCB printing, including drilling functionality for vias and through-holes.</li></ul></li><li id="">What material was used in this project?some text<ul id=""><li id="">The ink we used for this print is, <a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml" id="">Conductor 3</a>, a silver-based and semi-sintering ink that provides strong conductivity after curing.</li></ul></li><li id="">What nozzles should be used?&nbsp;some text<ul id=""><li id="">We generally recommend using a nozzle with a diameter that is at least six times larger than the average particle size in your ink.&nbsp;</li></ul></li></ul><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67782cbaeec7a93878566940_67782c6dd15762c9ca554af9_webinar-recap-printing-pcbs-digital-counter.webp" loading="lazy" alt="__wf_reserved_inherit" width="auto" height="auto" id=""></div><figcaption id="">V-One printing the digital counter board</figcaption></figure><h2 id="">Additional resources</h2><p id="">Excited to try this project? Download Gerber files <a href="https://5264434.fs1.hubspotusercontent-na1.net/hubfs/5264434/_Sales%20(SALE)/Sales_Assets/ITIZ%20parts%20list%20and%20design%20files.zip?utm_campaign=Demo%20Webinar&utm_source=hs_email&utm_medium=email&_hsenc=p2ANqtz--3uwhwvbGFcPVzB998QlxbgUNz4eIdljcVnFTdGHObjSk-D5gBBkLuUHAA49BSVmlUiNw3" id="">here</a>.&nbsp; Interested in other projects to teach the basics of PCB prototyping? Check out these resources:</p><ul id=""><li id="">Tutorial: <a href="https://docs.voltera.io/v-one/getting-started/hello-world-project" id="">Printing a Basic LED Circuit Using the V-One PCB Printer</a></li><li id="">Tutorial: <a href="https://docs.voltera.io/v-one/getting-started/punk-console-project">Printing a Punk Console Using the V-One PCB Printer</a></li><li id="">White paper: <a href="https://www.voltera.io/applications/flexible-pcbs" id="">Printing a Flexible PCB with Silver Ink on PET</a></li><li id="">Video: <a href="https://youtube.com/playlist?list=PLbZdiubRTqoqS9CDbZrtc5kbc-bhfKdUw&si=TpSbDWjqoyVp_tcQ">Other Voltera webinars on additive electronics</a></li><li>Blog: <a href="https://www.voltera.io/blog/prototype-pcbs-in-house">How to Prototype PCBs In-House</a></li></ul><p id="">To discuss your PCB prototyping needs, contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=webinar-recap-printing-pcbs-learning&utm_content=book-a-meeting" id="">book a meeting</a>. To stay informed on upcoming webinars, <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a" id="">subscribe to our newsletter</a>!&nbsp;</p>

Webinar Recap: Printing PCBs for Hands-On Learning 

This webinar showcased the process of printing a single-sided PCB as part of an educational project for teaching the fundamentals of electronics development. 

Webinar Recap: Printing PCBs for Hands-On Learning

This webinar showcased the process of printing a single-sided PCB as part of an educational project for teaching the fundamentals of electronics development.

<p id="">In a recent webinar, we demonstrated the process of dispensing in-mold electronics (IME) ink onto a polycarbonate substrate. This was achieved using <a href="https://www.voltera.io/nova" id="">NOVA</a>, our direct-ink write printer designed for high-resolution materials dispensing and flexible hybrid electronics prototyping.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6765e4e7efa24f7e2cab3be6_6765e40dff15f5e90502d3fd_webinar-printing-in-mold-electronic-prototypes.webp" loading="lazy" alt="webinar image" width="auto" height="auto" id=""></div><figcaption id="">Webinar: Printing in-mold electronic prototypes for automotive applications</figcaption></figure><h2 id="">Webinar highlights</h2><h3 id="">Overview of the industry</h3><p id="">Our Support Lead, Nathan Shinkar, kicked off the webinar with a brief overview of the in-mold electronics industry, discussing its market size, typical applications, and ink property requirements.</p><h3 id="">Overview of the project and best practices</h3><p id="">Nathan then walked through the steps to complete the final product — an automotive console — including:</p><ol id=""><li id="">Preparing the circuit design and ink</li><li id="">Calibrating the ink</li><li id="">Printing the ink on polycarbonate</li><li id="">Curing the circuit in an oven</li><li id="">Post-processing</li><li id="">Injection molding</li></ol><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6765e4e6efa24f7e2cab3b87_6765e4334e7babbc9ab68ed4_webinar-printing-ime-prototypes-automotive-console.webp" loading="lazy" alt="Nathan showing the automotive console final product" width="auto" height="auto" id=""></div><figcaption id="">Automotive console, final product</figcaption></figure><p id="">Once the process was explained, Nathan shared best practices for printing similar IME projects to ensure durability and functionality.</p><h3 id="">Dispensing thermoformable conductive ink on polycarbonate</h3><p id="">Since we covered the calibration workflow in previous webinars, such as <a href="https://www.voltera.io/blog/webinar-recap-printing-wearable-electronics" id="">Printing Wearable Electronics</a>, we instead focused on a live demonstration of dispensing <a href="https://store.voltera.io/products/elantas-bectron-cp-6680-2ml-cartridge-copy?srsltid=AfmBOoqiamG1bo1YJ7BX-Z6OdjOaibfOLVlASR1tU30O7pH3ZdNP6x4s" id="">Bectron® CP 6680 thermoformable conductive silver ink</a>, made by <a href="https://www.elantas.com/" id="">Elantas</a>.&nbsp;</p><p id="">The process began with generating a height map for the polycarbonate substrate, followed by a flow check to ensure proper ink flow and confirm the nozzle was unclogged. NOVA then took care of dispensing the ink. After printing the circuit, Nathan inspected the print quality using NOVA’s high-resolution camera and was pleased with the precise quality.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6765e4e6efa24f7e2cab3b84_6765e45a8d7106c80e3f4040_webinar-printing-ime-prototypes-inspect-print.webp" loading="lazy" alt="Viewing print quality in the NOVA software" width="auto" height="auto" id=""></div><figcaption id="">Inspecting print quality in the NOVA software</figcaption></figure><h2 id="">Conclusion</h2><p id="">This webinar highlighted the immense potential of IME applications in the automotive industry, but their possibilities extend far beyond. IME technology can also be applied to consumer electronics, home appliances, industrial equipment, and more. NOVA’s capability to dispense IME inks on flexible and thermoformable substrates opens the door to even more innovative opportunities.</p><p id="">Special thanks to Philipp and Ben, Technical Sales Managers at ELANTAS, and Benjamin Redford, Founder and CPO at Mayku, for answering questions throughout the webinar! Last but not least, thank you to everyone who participated and asked thought-provoking questions.</p><p id="">Didn’t make it to the webinar? Watch it here: </p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=FER16I0GlLk"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/FER16I0GlLk" title="Webinar: Printing In Mold Electronic Prototypes for Automotive Applications"></iframe></div></figure><p id="">Interested to learn more about IME? Check out the following resources:</p><ul id=""><li id="">Blog: <a href="https://www.voltera.io/blog/in-mold-electronics" id="">What Is In-Mold Electronics?</a></li><li id="">Video: <a href="https://youtube.com/playlist?list=PLbZdiubRTqoqS9CDbZrtc5kbc-bhfKdUw&si=TpSbDWjqoyVp_tcQ" id="">Other Voltera webinars on additive electronics</a></li><li id="">Market report: <a href="https://www.verifiedmarketresearch.com/product/in-mold-electronics-market/#:~:text=In%2DMold%20Electronics%20Market%20Size%20And%20Forecast,forecasted%20period%202024%20to%202031." id="">In-Mold Electronics Market Size and Forecast</a></li></ul><p id="">We offer <a href="https://www.voltera.io/printing-service?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=webinar-recap-ime-automotive&utm_content=paas" id="">printing as a service</a>, where we can create flexible hybrid electronics prototypes for you. To discuss your in-mold electronics prototyping needs, contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=webinar-recap-ime-automotive&utm_content=book-a-meeting" id="">book a meeting</a>. To stay informed on upcoming webinars, <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=link&utm_term=subscribe-to-newsletter&utm_content=webinar-recap-wearable-electronics" id="">subscribe to our newsletter</a>!&nbsp;</p>

Webinar recap: Printing In-Mold Electronic Prototypes

Learn about dispensing in-mold electronics ink on thermoformable polycarbonate for IME applications in the automotive industry from our recent webinar. 

Webinar Recap: Printing In-Mold Electronic Prototypes

Learn about dispensing in-mold electronics ink on thermoformable polycarbonate for IME applications in the automotive industry from our recent webinar.

<p>In the ever-evolving landscape of advanced manufacturing and material deposition, screen printing and direct ink writing (DIW) have emerged as two prominent technologies. Both techniques have found applications across various industries, including <a href="https://www.voltera.io/applications/electroluminescent-displays">display electronics</a>, <a href="https://www.voltera.io/applications/bioelectronics">biomedical devices</a>, and <a href="https://www.voltera.io/applications/printed-batteries">energy storage systems</a>.&nbsp;</p><p>Understanding the differences between these two methods is crucial for selecting the appropriate technology for specific applications. This blog will explore the key differences, advantages, and limitations of screen printing and DIW.</p><h2>Screen printing</h2><p>Screen printing is a well-established technique widely used in the field of printed electronics. It involves the use of a mesh screen to transfer conductive inks, dielectric pastes, or other functional materials onto a substrate, except in areas made impermeable by a blocking stencil. The ability to print a variety of materials, such as silver, carbon, and dielectric inks, makes screen printing essential for <a href="https://www.voltera.io/blog/flexible-hybrid-electronics">flexible</a> and rigid electronics.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520ec3aadd17a2036bb6cb_67520e7f46347380734069e5_screen-printing-diw-stencil-squeegee-ink.webp" loading="lazy" alt="A screen printer" width="auto" height="auto"></div><figcaption>Screen printing</figcaption></figure><h3>How screen printing works</h3><p>The screen printing process in printed electronics involves several key steps:</p><ol><li>Screen preparation: A mesh screen is coated with a photosensitive emulsion and a stencil of the desired circuit pattern is created by exposing the emulsion to light through a film positive. The unexposed areas of the emulsion are washed away, leaving a stencil that defines the electronic pattern on the screen.</li><li>Ink application: Conductive or functional ink is placed on the screen, and a squeegee is used to press the ink through the mesh openings, transferring the pattern onto substrates such as <a href="https://store.voltera.io/products/pet-5-sheets">PET</a>, <a href="https://store.voltera.io/products/polyimide-5-sheets">polyimide</a>, or other materials commonly used in electronics.</li><li>Curing: The printed substrate is typically cured using heat, UV light, or other methods to solidify the ink and ensure proper conductivity and adhesion.</li></ol><h3>Advantages of screen printing in printed electronics</h3><ul><li>Scalability: Screen printing is ideal for large-scale production of printed electronics, such as <a href="https://www.voltera.io/application-whitepapers/printing-rfid-tag-copper-ink-paper">RFID antennas</a>, <a href="https://www.voltera.io/application-whitepapers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet">flexible circuits</a>, and <a href="https://www.voltera.io/application-whitepapers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">wearable sensors</a>, offering a cost-effective solution for mass manufacturing.</li><li>Versatility: Screen printing supports a wide range of conductive, resistive, and insulating materials, allowing for the fabrication of diverse electronic components on various substrates, including flexible and rigid surfaces.</li><li>Thick film deposition: Screen printing excels in depositing relatively thick layers of conductive or dielectric inks, which is advantageous in applications like thick-film resistors and printed circuit boards where material build-up is essential for functionality.</li></ul><h3>Limitations of screen printing</h3><ul><li>Costs: Initial setup costs, including screen preparation and stencil creation, can be high, especially for small runs or frequent design changes. Specialized inks are also costly, and material waste, particularly of expensive inks, adds significantly to the overall expense.</li><li>Resolution: The resolution of screen printing is constrained by the mesh size, limiting the minimum achievable line widths and spacing. This makes it challenging for applications requiring fine feature sizes, such as advanced microelectronics.</li><li>Complexity in multilayer printing: While screen printing is capable of creating multilayer structures, aligning each layer accurately is critical and can be complex. Misalignments can lead to electrical short circuits or open connections, impacting the performance of printed electronic devices.</li></ul><h2>Direct ink writing</h2><p>DIW is an additive manufacturing process that deposits conductive inks, solder pastes, and other functional materials onto substrates, layer by layer. Similar to screen printing, DIW technology is compatible with a wide variety of materials, but unlike screen printing, which prints entire patterns at once, DIW creates patterns feature-by-feature. This allows DIW machines like <a href="https://www.voltera.io/nova">NOVA</a> to offer precise control of the material dispensed and makes it ideal for prototyping and customization of printed electronics.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520ec3aadd17a2036bb6be_67520e6e545e0807f3636280_screen-printing-diw-direct-ink-writing.webp" loading="lazy" alt="Direct ink writing of a circuit" width="auto" height="auto"></div><figcaption>Direct ink writing</figcaption></figure><h3>How direct ink writing works</h3><p>The DIW process in printed electronics involves the following steps:</p><ol><li>Ink/paste preparation: Depending on the material, inks or pastes may need purging to remove trapped air. For solder pastes, it's crucial to let the cartridge reach room temperature before dispensing.</li><li>Dispensing: The ink is extruded through a nozzle, following precise paths controlled by software. The nozzle moves relative to the substrate, dispensing material onto specific areas to create intricate electronic patterns layer by layer.</li><li>Curing: The dispensed material is typically solidified through heat or UV light, ensuring the conductivity and stability required for electronics to function.</li></ol><h3>Advantages of direct ink writing in printed electronics</h3><ul><li>High precision: DIW offers high resolution, allowing for the creation of fine, detailed features that are ideal for intricate electronic patterns and components. This precision makes it suitable for applications requiring meticulous design and control over material placement.</li><li>Material versatility: DIW printing supports a variety of materials, including conductive inks, composites, epoxies, encapsulants, and multi-materials, enabling complex and functional electronic structures.</li><li>Customization: DIW is perfect for prototyping and small-batch production, offering flexibility and easy design adjustments, ideal for custom electronic applications.</li><li>Scalability to screen printing: DIW is highly compatible with screen-printable inks or pastes, making it easy to transition from prototyping with DIW to large-scale deployment with screen printing.</li></ul><h3>Limitations of direct ink writing in printed electronics</h3><ul><li>Speed: Although the setup process is simpler, DIW builds patterns feature by feature, making it slower compared to the rapid, full-pattern deposition of screen printing.&nbsp;</li><li>Material preparation: DIW relies on ink cartridges, which may run out during the printing process, requiring frequent reloading and causing downtime for material changeovers. This can interrupt the workflow.</li><li>Scale: Due to the workflow of DIW, scaling up to mass production is challenging compared to screen printing.</li></ul><h2>Screen printing vs. DIW: When to choose which?</h2><p>The choice between screen printing and DIW in printed electronics depends on the specific needs of your application. Screen printing is well-suited for high-volume production where speed and cost-efficiency of manufacturing are crucial. As such, it’s ideal for large-scale manufacturing of electronics.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520ec3aadd17a2036bb6db_67520ea8e4bf526f3c7b988f_screen-printing-diw-large-scale-manufacturing.webp" loading="lazy" alt="Mass manufacturing of PCBs" width="auto" height="auto"></div><figcaption>Large-scale manufacturing of PCBs</figcaption></figure><p>On the other hand, DIW is the preferred choice for applications that require high precision, customization, and the ability to work with advanced materials. Applications such as biomedical devices and microelectronics can benefit from DIW due to its ability to create complex geometries and functional structures, especially during the prototyping stage when frequent design changes are common.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520ec3aadd17a2036bb6af_67520eb8bd013209a9e0e3f3_screen-printing-direct-write-customized-electronics.webp" loading="lazy" alt="High-precision and highly customized electronics" width="auto" height="auto"></div><figcaption>High-precision and customized prototyping</figcaption></figure><p>Using the NOVA materials dispensing system as an example, here’s how it stacks up against screen printing:</p><p>[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/67a25d5dd1f78a9bfd7d8259_efdc0dbf70268bf7313a52a5d1aef0cc_Blog_Screen%20printing%20vs%20DIW_table%201.txt[/script]</p><h2>Conclusion</h2><p>Deciding between screen printing and DIW comes down to what your project needs most. Knowing the strengths and limitations of each method helps you match the right technology to your design goals, whether you're focusing on scalability, precision, or working with advanced materials in printed electronics.&nbsp;</p><p>For more information on technologies in printed electronics, check out the following blogs:</p><ul><li><a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">Introduction to Direct Ink Writing (DIW) Printing Technology</a></li><li><a href="https://www.voltera.io/blog/introduction-screen-printing">Introduction to Screen Printing</a></li><li><a href="https://www.voltera.io/blog/introduction-inkjet-technology">Introduction to Inkjet Technology</a></li><li><a href="https://www.voltera.io/blog/introduction-to-gravure-printing-technology">Introduction to Gravure Printing Technology</a></li></ul><p>Meanwhile, if you have questions about your PCB printing needs, please contact us at <a href="mailto:sales@voltera.io">sales@voltera.io</a> or <a href="https://www.voltera.io/book-a-meeting">book a meeting with us</a>!</p><h2>References</h2><p>[1] <a href="https://www.pcb-hero.com/blogs/lickys-column/the-importance-of-pcb-trace-widths-in-pcb-design?utm_source=chatgpt.com">The Importance of PCB Trace Widths in PCB Design</a>.</p><p>[2] <a href="https://www.silkscreenprintingsupply.com/news/influence-of-screen-parameters-on-printing-film-thickness?utm_source=chatgpt.com">Influence of screen parameters on printing film thickness</a>.</p>

Screen Printing vs. Direct Ink Writing for Printed Electronics

Discover the differences and similarities between screen printing and direct ink writing, in terms of their workflow, advantages, and limitations.

<p id="">Twenty years ago, the idea of integrating electronics into devices seemed impossible — or, at least, very expensive. As new additive manufacturing methods like Voltera’s <a href="https://www.voltera.io/nova" id="">NOVA</a> platform are introduced to the market, those newer, lighter, smaller, and more complex designs are becoming a reality.&nbsp;</p><h2 id="">Definition of in-mold electronics</h2><p id="">In-mold electronics (IMEs) is the process of incorporating electronic elements into molded plastic objects. It typically consists of the following process:</p><ol id=""><li id="">Printing a thermoformable circuit</li><li id="">Thermoforming the circuit into a designated 3D shape</li><li id="">Injecting a thermoplastic polymer to encapsulate the electronic devices</li></ol><p id="">Depending on their end use, IMEs can include all the surface-mount devices (SMDs) included in traditional electronics to increase functionality, such as sensors, LEDs, and microcontrollers. SMDs are usually placed on the circuit before thermoforming. The final product is a functional, rigid plastic component.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520e0949ffc696dd647248_67520cd40832bcd40e723cab_in-mold-electronics-definition.webp" loading="lazy" alt="A plastic box being Injection molded" width="auto" height="auto" id=""></div><figcaption id="">Injection molding</figcaption></figure><h2 id="">Market potential of in-mold electronics</h2><p id="">IMEs offer unparalleled design freedom, allowing for sleek, modern, and lightweight designs that maintain high functionality, creating an excellent user experience. These electronics are water, scratch, and chemically resistant, making them highly durable and ideal for applications in harsh environments. Additionally, the highly automated workflow of IMEs can reduce manufacturing, assembly, and maintenance costs.</p><p id="">As a more sophisticated solution compared to the traditional approach of mounting rigid printed circuit boards (PCBs) inside rigid enclosures, IMEs are becoming increasingly popular in human-machine interface (HMI) applications in the automotive, medical equipment, aerospace, and consumer electronics <a href="https://www.voltera.io/use-cases/industries">industries</a>. According to the report "<a href="https://www.idtechex.com/en/research-report/in-mold-electronics-2023-2033/919" target="_blank">In-Mold Electronics 2023-2033</a>" by IDTechEx, the market for IMEs is forecasted to reach around USD $2 billion by 2033.&nbsp;</p><h2 id="">Applications</h2><h3 id="">Automotive industry</h3><p id="">IME technology in the automotive sector is used to design sophisticated HMIs, including touch-sensitive dashboards, integrated lighting, and control panels. These designs eliminate traditional mechanical buttons, wires, and connectors, allowing for a streamlined, button-free interface. The resulting designs are not only visually clean but also functionally integrated, blending seamlessly with the vehicle's interior.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6752068484bbcc4a5c211f1c_675206633cf6159d9b9caf7b_warming-coffee-in-mold-structural-electronics-automotive-console.webp" loading="lazy" alt="Automotive IME" width="auto" height="auto" id=""></div><figcaption id="">Application of IME in automotives (image: <a href="https://unsplash.com/photos/black-car-door-with-black-lever-AHyZ9cQW3ZU" id="">Markus Spiske</a>)</figcaption></figure><h3 id="">Consumer Electronics</h3><p id="">In consumer electronics, IME is applied to products such as headphones, smartwatches, fitness trackers, and smart home devices. <a href="https://www.tactotek.com/" id="">Tactotek</a>, for example, has utilized IME technology to develop headphones with a thin, transparent user interface set into a curved plastic frame. This design emphasizes minimalism and subtle integration of electronic controls. The touch controls and responsive lights are discreetly incorporated, providing an intuitive and straightforward user experience.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520e0949ffc696dd64723d_67520dfcafa41b8c122fdbf4_in-mold-electronics-consumer-electronics.webp" loading="lazy" alt="IME application in consumer electronics" width="auto" height="auto" id=""></div><figcaption id="">Application of IME in consumer electronics</figcaption></figure><h2 id="">Inks for in-mold electronics</h2><p id="">Conductive inks, dielectric inks, and conductive adhesives used in IMEs must withstand the thermoforming and injection molding processes, requiring resistance to high temperatures, pressure, and elongation. <a href="https://store.voltera.io/products/elantas-bectron-cp-6680-2ml-cartridge-copy">Conductive inks</a>, in particular, need to provide high electrical conductivity, low contact resistance, and good adhesion. To ensure compatibility and optimal performance, it is advisable to select inks from the same supplier.</p><p id="">A few ink suppliers that make inks for IMEs include:&nbsp;</p><ul id=""><li id=""><a href="https://www.celanese.com/products/micromax" target="_blank" id="">Celanese</a></li><li id=""><a href="https://www.creativematerials.com/thermoformable-in-mold-compatible-electrically-conductive-ink/" target="_blank" id="">Creative Materials</a></li><li id=""><a href="https://www.dycotecmaterials.com/products/in-mold-electronic-inks/" target="_blank" id="">Dycotec Materials</a></li><li id=""><a href="https://www.genesink.com/applications/in-mold-electronics/" target="_blank" id="">GenesInk</a></li></ul><h2 id="">Conclusion</h2><p id="">As the market for IME technology continues to grow, its potential to enhance user experiences and improve product performance is increasingly recognized. To learn more about IMEs, check out these resources:</p><ul id=""><li id=""><a href="https://www.idtechex.com/en/research-report/in-mold-electronics-2023-2033/919" target="_blank" id="">In-Mold Electronics 2023-2033</a></li><li id=""><a href="https://www.idtechex.com/en/research-article/unravelling-competing-in-mold-electronics-manufacturing-methodologies/29146" target="_blank" id="">Unravelling Competing In-Mold Electronics Manufacturing Methodologies</a></li><li id=""><a href="https://www.industryarc.com/Research/in-mold-electronics-ime-market-research-800274" id="">In-Mold Electronics (IME) Market Report</a></li></ul><p id="">Want the latest news in printed electronics? <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a" id="">Subscribe to our newsletter</a>. If you have questions about additive prototyping and low volume manufacturing of electronics , please <a href="mailto:sales@voltera.io" id="">contact us</a>.</p>

What Is In-Mold Electronics?

As electronics evolve, in-mold electronics are becoming more common. In this article, we discuss the market potential, explore applications, and outline ink requirements.

<p id="">Choosing the right development platform for your electronics project can significantly impact its efficiency and success rates. Breadboards and printed circuit boards (PCBs) each offer unique advantages suited to different stages of development. This blog will explore the key differences between the two in terms of definitions, materials and substrates, manufacturing processes and costs, as well as benefits and applications, helping you make informed decisions for your electronics projects.</p><h2 id="">Definitions</h2><h3 id="">What are breadboards?</h3><p id="">Breadboards, also known as protoboards, consist of a perforated plastic board with a grid of holes where components can be inserted. The central area of the breadboard is divided into rows, each with internal electrical connections, allowing components placed in the same row to be connected without soldering. Separate vertical columns, known as power rails, line the outer edges to facilitate easy power distribution across the board.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa72227488846090_67520921bb35ff6ae6d321f1_breadboards-pcbs-definitions-materials-costs-benefits-applications-definition.webp" loading="lazy" alt="A breadboard with components connected to an Arduino Uno board" width="auto" height="auto" id=""></div><figcaption id="">A breadboard connected to an Arduino Uno</figcaption></figure><h3 id="">What are PCBs?</h3><p id="">Printed circuit boards mechanically support and electrically connect electronic components through conductive tracks, pads, and other features. PCBs are a crucial component in any electronic device.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8caa72227488846064_6752097539389a8a6d2a45b9_breadboards-pcbs-definitions-materials-costs-benefits-applications-what-pcbs.webp" loading="lazy" alt="An Arduino Leonardo printed circuit done with V-One" width="auto" height="auto" id=""></div><figcaption id="">An Arduino Leonardo printed circuit done with V-One</figcaption></figure><h2 id="">Types of PCBs</h2><p id="">In modern electronics, single-layer, double-layer, and multilayer PCBs are common, each offering varying levels of complexity and functionality. Among these, several types of PCBs stand out for their popularity: breakout boards, template boards, and development boards.</p><h3 id="">Breakout boards</h3><p id="">Breakout boards are compact PCBs designed to provide easy access to the pins of an integrated circuit or other components. They "break out" the connections from a single component or chip to a more manageable layout, typically with larger, more accessible pins. This design makes it easier to integrate specific components into your projects without dealing with very small or densely packed pins.</p><h3 id="">Template and development boards</h3><p id="">Template boards, also known as development boards, are pre-designed PCBs equipped with common microcontrollers or other integrated circuits (ICs), along with the necessary circuitry to support programming and prototyping. Examples include:</p><ul id=""><li id=""><a href="https://store.voltera.io/products/arduino-uno-template?_pos=9&_fid=a687361e0&_ss=c" id="">Arduino</a></li><li id=""><a href="https://store.voltera.io/products/raspberry-pi-b-template?_pos=11&_fid=a687361e0&_ss=c" id="">Raspberry Pi</a></li><li id=""><a href="https://store.voltera.io/products/particle-photon-template?_pos=12&_fid=a687361e0&_ss=c" id="">Particle</a></li><li id=""><a href="https://store.voltera.io/products/feather-templates?_pos=13&_fid=a687361e0&_ss=c" id="">Adafruit</a></li></ul><p id="">These boards offer a standardized platform for building and testing projects, facilitating rapid development, and experimentation.</p><h3 id="">PCBA</h3><p id="">It is worth noting that a printed circuit board assembly (PCBA) is not the same as a PCB. While a PCB is not functional on its own, a PCBA includes the PCB itself and all the components soldered onto it, making it a complete and functional assembly for its intended application.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa72227488846081_675209c16306a7bbec9b6d48_breadboards-pcbs-definitions-materials-costs-benefits-applications-pcba.webp" loading="lazy" alt="A PCBA" width="auto" height="auto" id=""></div><figcaption id="">A PCBA</figcaption></figure><h2 id="">Differences between PCBs and breadboards</h2><h3 id="">Materials and substrates</h3><h4 id="">Breadboards</h4><p id="">Breadboards are primarily made from a plastic body featuring numerous holes with metal strips underneath. These strips are usually made of spring metal to create a temporary electrical connection when the leads of components are inserted into the holes. Breadboards are inherently rigid due to their plastic construction, and are typically not used with flexible materials.</p><h4 id="">PCBs</h4><p id="">Traditional PCBs are typically made from layers of fiberglass reinforced with epoxy resin, known as <a href="https://store.voltera.io/products/3-x-4-substrates" id="">FR4</a>. This material provides a sturdy, non-conductive substrate. The conductive paths are generally made of copper etched onto the board to form tracks that electrically connect components.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa7222748884608d_67520a129b2a0e79f58852c7_breadboards-pcbs-definitions-materials-costs-benefits-applications-pcbs.webp" loading="lazy" alt="PCBs with gold finish" width="auto" height="auto" id=""></div><figcaption id="">PCB boards</figcaption></figure><h4 id="">Flexible PCBs</h4><p id=""><a href="https://www.voltera.io/use-cases/applications/flexible-pcbs" id="">Flexible PCBs</a> represent a variant of standard PCBs, made from materials that allow them to bend, flex, and move without breaking. Typically constructed from a flexible high-performance plastic like polyimide, these PCBs incorporate conductive copper layers and, in many cases, dielectric layers to ensure electrical insulation and mechanical strength.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8caa72227488846061_67520a586db6a2a7ac25bd2d_breadboards-pcbs-definitions-materials-costs-benefits-applications-flexible-pcbs.webp" loading="lazy" alt="Flexible PCBs" width="auto" height="auto" id=""></div><figcaption id="">Flexible PCBs printed on <a href="https://www.voltera.io/nova" id="">NOVA</a></figcaption></figure><h3 id="">Manufacturing processes and costs</h3><h4 id="">Breadboards</h4><p id="">Breadboards require no manufacturing for individual projects since they are reusable and do not need to be customized. This makes them cost-effective for initial testing and development. Prices generally range from a few dollars for basic models to higher amounts for larger or specialty types.</p><h4 id="">PCBs</h4><p id="">PCBs, on the other hand, involve a complex manufacturing process. This includes designing the circuit layout, printing the design onto the substrate, etching copper layers, drilling holes, and sometimes adding a protective solder mask and silk-screening component labels. The cost of producing PCBs can vary widely depending on the complexity of the design, the number of layers, and the quantity produced. While unit costs decrease with larger batch sizes, the initial setup and design work can be costly.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa72227488846084_67520ab360512214fbe01e99_breadboards-pcbs-definitions-materials-costs-benefits-applications-manufacturing-pcbs.webp" loading="lazy" alt="Traditional fabrication of PCBs" width="auto" height="auto" id=""></div><figcaption id="">Traditional fabrication of PCBs</figcaption></figure><p id="">The manufacturing of PCBs in a traditional factory setting is often not the most efficient approach, particularly when the process involves multiple iterations in quick succession. In such cases, the <a href="https://www.voltera.io/v-one" id="">Voltera V-One PCB printer</a> can be extremely useful. It allows users to modify their PCB designs on the fly and produce up to 15 boards in one day, while also ensuring that the design files and intellectual property remain secure.&nbsp;</p><h3 id="">Workflows</h3><h4 id="">Breadboards</h4><p id="">Breadboards are straightforward to use and require no special tools, making them ideal for beginners and those testing concepts or learning about circuits. Their non-permanent nature allows for easy adjustments and corrections without additional cost.</p><h4 id="">PCBs</h4><p id="">PCBs, however, involve a significant upfront investment in design and planning. Designing a PCB typically requires using specialized software to lay out circuits, which can present a steep learning curve initially. However, for advanced projects and mass production, PCBs are more efficient once the initial setup is complete. They provide a more reliable and professional outcome, suitable for commercial products.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa72227488846087_67520afe113d928277a1e9f7_breadboards-pcbs-definitions-materials-costs-benefits-applications-workflows.webp" loading="lazy" alt="A PCB mounted on a breadboard" width="auto" height="auto" id=""></div><figcaption id="">A PCB mounted on a breadboard</figcaption></figure><h3 id="">Benefits and applications</h3><h4 id="">Breadboards</h4><p id="">Breadboards offer simplicity and flexibility, making them ideal for beginners and for educational purposes. They facilitate quick assembly and easy modifications of circuits without the need for soldering. This non-permanent setup is perfect for iterative testing and debugging, allowing users to learn and adjust as they go.</p><p id="">Breadboards are commonly used in educational settings to <a href="https://www.voltera.io/use-cases/white-papers/printing-decimal-counter-circuit-silver-conductive-ink-fr1" id="">teach electronics</a>, in hobbyist projects for experimenting with new circuit designs, and during the prototype testing phase of electronic development, especially when frequent adjustments are anticipated. Examples of projects using breadboards include FM radio transmitters, LED cubes, and digital thermometers.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa7222748884608a_67520b41bda1cb8a2508c79c_breadboards-pcbs-definitions-materials-costs-benefits-applications-benefits.webp" loading="lazy" alt="Breadboards and electronic components" width="auto" height="auto" id=""></div><figcaption id="">Breadboards and electronic components</figcaption></figure><h4 id="">PCBs</h4><p id="">PCBs provide enhanced durability and reliability, supporting complex and <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova" id="">multi-layered circuit designs</a> with dense component placement, essential in professional-grade electronics. They are designed to handle more permanent and advanced applications, ensuring consistent performance over time.</p><p id="">PCBs are crucial in <a href="https://www.voltera.io/use-cases/industries" id="">various industries</a>, including consumer electronics, medical devices, automotive components, and other demanding applications that require long-term reliability and efficiency under varying environmental conditions. Examples of these applications include advanced driver-assistance systems, MRI scanners, and the flight control systems of drones.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520b8eaa72227488846093_67520b80113d928277a27fb0_breadboards-pcbs-definitions-materials-costs-benefits-applications-benefits-pcbs.webp" loading="lazy" alt="A PCBA for a robotic hand" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.voltera.io/blog/building-a-remote-controlled-robotic-hand-with-strain-gauges" id="">A PCBA for a remote control robotic hand made with V-One and NOVA</a></figcaption></figure><h2 id="">Conclusion</h2><p id="">Both breadboards and PCBs play essential roles in electronics development. Breadboards are perfect for prototyping, testing, and educational purposes due to their flexibility and ease of use. On the other hand, PCBs are indispensable for final product development, offering stability, reliability, and suitability for complex and high-frequency circuits.&nbsp;</p><p id="">Understanding the strengths and limitations of each tool will help you choose the right one for your project, ensuring success in your electronics endeavors.&nbsp;</p><p id="">For more information on additively printed circuit boards, check out the following resources:</p><ul id=""><li id="">White paper: <a href="https://www.voltera.io/application-whitepapers/printing-magnesium-zinc-battery-saral-inks-pet">Printing a Magnesium Zinc Battery with Saral Inks on PET</a></li><li id="">White paper: <a href="https://www.voltera.io/application-whitepapers/printing-electroluminescent-ink-paper-pet">Printing Electroluminescent Ink on Paper and PET</a></li><li id="">White paper: <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><li id="">Blog: <a href="https://www.voltera.io/blog/webinar-recap-printing-electronics-with-carbon-ink">Printing Electronics with Carbon Ink</a></li><li>Blog: <a href="https://www.voltera.io/blog/prototype-pcbs-in-house">How to Prototype PCBs In-House</a></li></ul><p id="">Meanwhile, if you have questions about your PCB printing needs, please contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a>.</p>

Breadboards vs. PCBs: Definitions, Materials, Costs, Benefits, and Applications

Discover the differences and similarities between breadboards and printed circuit boards, in terms of materials, costs, benefits, applications and more. 

Breadboards vs. PCBs: Materials, Costs, and Applications

Discover the differences and similarities between breadboards and printed circuit boards, in terms of materials, costs, benefits, applications and more.

<p id="">In our latest webinar, we dove into the process of dispensing T4 solder paste onto factory-fabricated circuit boards using the <a href="https://www.voltera.io/v-one" id="">V-One PCB printer </a>— a key innovation in PCB prototyping that streamlines PCB assembly.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=v5WuA4h4fN0"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/v5WuA4h4fN0" title="Webinar: Dispensing Solder Paste on Factory Fabricated PCBs"></iframe></div></figure><h2 id="">Precision solder paste dispensing</h2><p id="">The webinar focused on V-One’s solder paste dispensing workflow. With features like aligned dispensing, selective printing, and an integrated heated bed, the V-One simplifies the often complex and messy process of applying solder paste, making <a href="https://www.voltera.io/use-cases/applications/additive-pcb-prototyping" id="">PCB prototyping</a> accessible for everyone.</p><h2 id="">Webinar highlights</h2><h3 id="">Live demonstration</h3><p id="">We kicked off with a live demonstration of V-One in action, showcasing the paste setup process, dispensing solder paste onto the PCB, and even correcting unsatisfactory results on the fly. This real-time demo highlighted the ease of using V-One’s software and the precision of the dispensing process, emphasizing its role in reducing manual errors and improving consistency in PCB assembly.</p><h3 id="">Workflow overview</h3><p id="">The session provided a comprehensive overview of the entire solder paste dispensing workflow, including the alignment of the factory-fabricated board, dispensing the solder paste, and performing reflow on the heated bed. Voltera’s support lead, <a href="https://www.linkedin.com/in/nathanshinkar/" id="">Nathan Shinkar</a>, shared tips on achieving optimal results with V-One, such as calibrating the machine and selecting the correct print settings.</p><h3 id="">Tips and tricks</h3><p id="">We also showcased a completed print with components populated, sharing tips and tricks on how to place the components to the right place of your own boards and cure the print on V-One, all guided by a detailed software walkthrough.</p><h2 id="">Conclusion</h2><p id="">As demonstrated by the webinar, the capabilities to dispense solder paste and reflow PCBs make V-One an ideal tool for PCB prototyping, whether it’s precise and repeatable dispensing of your selected paste, reworking your solder pads on the fly, or creating addons for your PCBAs.&nbsp;</p><p id="">Special thanks to everyone who joined and participated in the live chat. Your questions about solder paste selection, board alignment, and reflow processes helped make this webinar interactive and informative.&nbsp;</p><p id="">Interested to learn more? Check out the following resources:</p><ul id=""><li id="">Blog: <a href="https://www.voltera.io/blog/what-is-solder-paste" id="">What is Solder Paste?</a></li><li id="">White paper: <a href="https://www.voltera.io/application-whitepapers/dispensing-solder-paste-factory-fabricated-pcbs" id="">Dispensing Solder Paste on Factory Fabricated PCBs</a></li></ul><p id="">As mentioned in the webinar, we offer <a href="https://www.voltera.io/printing-service" id="">printing as a service</a>, where we can create your prototypes for you. To discuss your PCB printing needs, contact us at sales@voltera.io or <a href="https://www.voltera.io/book-a-meeting" id="">book a meeting with us</a>. To stay informed on upcoming webinars, <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a?__hstc=13863464.a6e861abd69863d5e355c083710f6ae2.1708615212577.1725990309429.1725995530379.319&__hssc=13863464.11.1725995530379&__hsfp=141023726" id="">subscribe to our newsletter</a>!&nbsp;</p>

Webinar recap: Dispensing Solder Paste on Factory-Fabricated PCBs

Learn more about our webinar on dispensing solder paste on factory fabricated boards using the Voltera V-One PCB printer.

<p id="">Researchers from Istituto Italiano di Tecnologia in Italy recently published a study in Nature where they utilized Voltera <a href="https://www.voltera.io/v-one" id="">V-One</a> PCB printer to print interdigital electrodes on a polydimethylsiloxane (PDMS) substrate, forming part of a three-layer piezoresistive sensor.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6776f11845b7946b3c2efb9a_66704a93f1a58c82efb10402_Research-using-VOne-PCB-printer-published-Nature.webp" loading="lazy" alt="Research Using V-One PCB Printer Published in Nature" width="auto" height="auto" id=""></div><figcaption>V-One PCB printer</figcaption></figure><h2 id="">The research problem</h2><p id="">This study aimed to formulate an eco-friendly conducting ink that maintains high electrical performance while being biodegradable. The ink formulation involves using biodegradable polylactic acid (PLA) as a matrix combined with conductive carbon nanotubes (CNTs) and silver flakes, to create a conducting ink suitable for flexible electronic devices.</p><h2 id="">The role of V-One</h2><p id="">The V-One was used to create eight-finger interdigitated electrodes on a PDMS substrate. V-One’s ability to handle conductive inks and produce intricate electrode patterns was vital in demonstrating the practical application and effectiveness of the newly developed biodegradable ink in flexible pressure sensors.</p><p id=""><a href="https://www.nature.com/articles/s41598-024-60315-z" target="_blank" id="">Read the full article</a></p><p id="">‍</p>

Research Using V-One PCB Printer Published in Nature

Read research conducted using the V-One PCB printer where researchers printed interdigital electrodes on PDMS, as part of a piezoresistive sensor. 

This research was conducted using the V-One PCB printer where researchers printed interdigital electrodes on PDMS, as part of a piezoresistive sensor. 

<p id="">In the world of additive fabrication, two technologies stand out for their transformative potential: 3D printing and PCB (printed circuit board) printing. They share the fundamental principle of additive manufacturing, but are different in a number of ways.&nbsp;</p><p id="">In this article, we will delve into the main differences between traditional 3D printing and additive PCB printing, as seen in machines like the Voltera <a href="https://www.voltera.io/v-one" id="">V-One</a>, in order to clarify their distinct roles in modern manufacturing.</p><h2 id="">How does 3D printing and PCB printing work?</h2><h3 id="">3D Printing</h3><p id="">With 3D printing, printers create objects by layering material, typically thermoplastic, from the bottom up. You begin with designing a model using computer-aided design (CAD) software. Next, you export the .stl file to your 3D printer software which will slice the model into thin horizontal layers, generating&nbsp; G-code for each layer. Depending on the type, your 3D printer will then extrude or solidify material layer by layer to form the final object.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be5b359aadbe103e20f21d_667048027567407f41e872d6_3D-printing-PCB-printing-difference-workflow.webp" loading="lazy" alt="3D printing workflow: step one - design, step two - slice, step three - print" width="auto" height="auto" id=""></div><figcaption id="">3D&nbsp;printing workflow</figcaption></figure><h3 id="">PCB printing</h3><p id=""><a href="https://www.voltera.io/use-cases/applications/additive-pcb-prototyping" id="">Additive PCB printing</a> shares similarities with 3D printing in terms of its workflow. Using electrical computer-aided design (ECAD) software, you design your project, then export the Gerber file and upload it to your printer’s software. PCB fabricators, such as V-One, will then interpret the Gerbers and deposit <a href="https://store.voltera.io/collections/materials?filter.p.m.custom.product_type=Inks" id="">conductive materials</a> to construct the layers of a printed circuit board.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be5b349aadbe103e20f215_6670484757c3abc5b1827714_3D-printing-PCB-printing-difference-VOne-software.webp" loading="lazy" alt="Voltera software displayed on a computer screen" width="auto" height="auto" id=""></div><figcaption id="">Viewing your project with V-One software</figcaption></figure><h2 id="">Key differences between 3D printing and PCB printing</h2><h3 id="">Materials and substrates</h3><p id="">The most apparent difference lies in the materials used. Traditional 3D printers work with a wide array of materials, including plastics such as PLA, PETG, TPU, ABS, and resin, as well as nylons and metals. In contrast, PCB printers utilize conductive inks, such as silver, copper, or graphite, and more to create functional circuit boards.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be5b359aadbe103e20f247_6670488d546fedb28555bcd4_3D-printing-PCB-printing-difference-Conductor-3.webp" loading="lazy" alt="Important update: Conductor 3, benefits include upright curing on the heated bed, 44% faster curing, and no burnishing required" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml" id="">Voltera Conductor 3 ink</a></figcaption></figure><p id="">While you can print a three-dimensional object directly on the heated bed of a 3D printer, PCB printing requires fixing a <a href="" id="">substrate</a> to the bed. Depending on your specific needs, you can choose more rigid substrates such as <a href="https://store.voltera.io/products/2-x-3-fr1-substrates" id="">FR1</a>, <a href="https://store.voltera.io/products/3-x-4-substrates" id="">FR4</a>, or more flexible ones such as <a href="https://store.voltera.io/products/intexar-tpu-5-sheets" id="">TPU</a>, paper or fabric.</p><h3 id="">Precision</h3><p id="">3D printers are generally used for larger objects and may not achieve the fine detail required for PCB manufacturing. The <a href="https://www.3erp.com/blog/how-dimensionally-accurate-are-3d-printed-parts/" target="_blank" id="">accuracy of desktop 3D printers</a> varies, ranging from ± 0.1 mm to ± 0.5 mm.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be5b359aadbe103e20f22d_667048d961a073c36efc7f3a_3D-printing-PCB-printing-difference-RFID-tag.webp" loading="lazy" alt="RFID tag print on paper using Copprint LF301 nano copper ink" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.voltera.io/blog/copper-rfid-tag" id="">RFID tag printed on paper</a></figcaption></figure><p id="">In contrast, PCB printers are designed for high precision, which is crucial for the intricate pathways and components of circuit boards. Notably, machines that use <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct-ink-writing technology</a>, such as <a href="https://www.voltera.io/nova" id="">NOVA</a>, enable the production of features as small as 100 µm.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be5b359aadbe103e20f24a_6670498fe92d6eb0734ce684_3D-printing-PCB-printing-difference-NOVA-traces.webp" loading="lazy" alt="Various print results using NOVA" width="auto" height="auto" id=""></div><figcaption id="">Details of conductive traces printed by NOVA</figcaption></figure><h3 id="">Capabilities and applications</h3><p id="">3D printers are handy when it comes to producing complex geometries and shapes. Some industries use 3D printing to manufacture the final product, such as architectural models, automotive parts, and dentures.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520881ebdcd6cdde502825_6752080b9b2a0e79f586433b_3d-printing-pcb-printing-difference-capabilities-applications.webp" loading="lazy" alt="A 3D printed arm brace" width="auto" height="auto" id=""></div><figcaption id="">A 3D-printed custom orthoses</figcaption></figure><p id="">However, these 3D printed projects, on their own, cannot perform functions such as sensing, monitoring, moving, amplifying, controlling, or mirroring, which require a printed circuit board and a range of electronic components. In order to test and iterate electronics projects, you will need a PCB printer.&nbsp;</p><p id="">The applications of PCB printers range from simple personal projects such as a weather station that monitors temperature, humidity, and atmospheric pressure, to complex R&amp;D endeavors such as a <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" id="">prototype for robotic arms</a> capable of performing surgeries.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520881ebdcd6cdde502835_67520867113d9282779ec55a_3d-printing-pcb-printing-difference-capabilities-applications-robot.webp" loading="lazy" alt="An AI robot" width="auto" height="auto" id=""></div><figcaption id="">A robot in a shopping mall in Kyoto</figcaption></figure><h3 id="">Costs</h3><p id="">Due to the differences in all the aforementioned aspects, these technologies are available at varying costs. Desktop 3D printers can be priced anywhere from <a href="https://formlabs.com/blog/how-to-calculate-3d-printer-cost/" target="_blank" id="">USD $200 to $2,500</a>, whereas desktop PCB printers tend to range from USD <a href="https://store.voltera.io/products/v-one">$3,499.99</a> to $27,800.</p><h2 id="">Conclusion</h2><p id="">3D printing allows for the creation of a broad spectrum of objects, whereas PCB printing offers a specialized, rapid, and cost-effective solution for circuit board production.&nbsp;</p><p id="">Despite their differences, 3D printing and PCB printing can be highly complementary. Leveraging these technologies together will streamline the electronics prototyping process.&nbsp;</p><p id="">As the technology continues to evolve, there is tremendous potential for further integration and innovation in both fields. For more insights on additive PCB manufacturing, check out these resources:</p><ul id=""><li id=""><a href="https://www.voltera.io/blog/what-is-printed-electronics-conductive-inks" id="">What is Printed Electronics? Conductive Inks</a></li><li id=""><a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">Introduction to Direct Ink Writing (DIW) Printing Technology</a></li><li id=""><a href="https://www.voltera.io/blog/introduction-inkjet-technology" id="">Introduction to Inkjet Technology</a></li><li id=""><a href="https://www.voltera.io/blog/introduction-screen-printing" id="">Introduction to Screen Printing</a></li><li id=""><a href="https://www.voltera.io/blog/resistance-resistivity-and-sheet-resistance" id="">Resistance, Resistivity &amp; Sheet Resistance</a></li><li id=""><a href="https://www.voltera.io/blog/prototype-pcbs-in-house" id="">How to Prototype PCBs In-House</a></li></ul><p id="">Meanwhile, if you have questions about your PCB printing needs, please contact us at <a href="mailto:sales@voltera.io" id="">sales@voltera.io</a>.</p>

3D Printing vs. PCB Printing — What’s the Difference?

Discover the differences and similarities between two additive technologies, 3D printing and PCB printing, in terms of materials, precision, and more.

<h2 id="">Voltera is one of Canada’s top emerging startups and a pioneer in additive electronics. </h2><p id="">The goal? Print electronics on anything and everything, opening up a world of possibilities.</p><p id="">Over the years, there’s been plenty of debate in the startup sphere over whether university is ‘worth it.’ The college dropout turned tech superstar is a much lauded story arc in Silicon Valley. However, for the co-founders of Waterloo-based <a href="https://www.voltera.io/about/about-us">Voltera</a>, university was not just worth it, but the genesis of their company.</p><p id="">What began as a school project by four University of Waterloo engineering students turned into one of Canada’s fastest-growing startups as Voltera blazes new trails in electronics.</p><p id="">Specifically, Voltera specializes in additive electronics, which have the potential to open up a world of possibilities like circuitry in sneakers to track your runs or parkas with <a href="https://www.voltera.io/blog/webinar-recap-printing-wearable-electronics">smart heated pockets</a> that respond to outside temperature. The goal is to print electronics on practically any material in a manner that’s also more sustainable than traditional manufacturing methods.<br><br><a href="https://www.rbcx.com/ideas/profiles/how-waterloos-voltera-is-upending-the-world-of-electronics/" target="_blank" id="">Keep reading...</a></p>

Voltera on RBCx: How Waterloo’s Voltera Is Upending the World of Electronics

Voltera specializes in additive electronics, which have the potential to open up a world of possibilities like circuitry in sneakers to track your runs or parkas with smart heated pockets that respond to outside temperature. The goal is to print electronics on practically any material in a manner that’s also more sustainable than traditional manufacturing methods.

<p id="">In this webinar, we hosted <a href="https://www.linkedin.com/in/andrew-bambach-17072793" id="">Andrew Bambach</a>, Engineering Manager at <a href="https://www.acimaterials.com/" id="">ACI Materials</a>, to explore cutting-edge advancements in printed electronics, focusing on flexible conductive inks and their transformative applications.&nbsp;</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=8k_DRhbHZGA"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/8k_DRhbHZGA" title="Webinar: Printing Electronics with Flexible Inks"></iframe></div></figure><h2 id="">Announcements</h2><p id="">During the webinar, our Support Lead, <a href="https://ca.linkedin.com/in/nathanshinkar" id="">Nathan Shinkar</a>, unveiled our new electronics <a href="https://www.voltera.io/printing-service" id="">printing service</a>. You can now outsource your novel electronics designs for cost-effective, precise prints without minimum order quantities. In addition, we have added more inks to <a href="https://store.voltera.io/collections/materials" id="">our store</a>. Because these inks cater to niche applications with smaller quantity requests, please inquire through the store to see if we have them in stock.</p><h2 id="">Webinar highlights</h2><h3 id="">Overview of ACI’s Alchemy inks</h3><p id="">Andy introduced <a href="https://www.acimaterials.com/wp-content/uploads/2021/07/ACI_Data_Sheet-Shared_Alchemy_Inks_1-1.pdf" id="">ACI’s Alchemy ink series</a>, emphasizing their unique semi-sintering technology that combines high conductivity (4–5 times better than polymer thick films) with low-temperature curing.&nbsp;</p><p id="">Key innovations of the Alchemy line include:</p><ul id=""><li id="">Cavitation process: A manufacturing method, proprietary to ACI Materials, which uses vacuum bubbles to disperse particles without damaging morphology, ensuring stable, clog-resistant inks</li><li id=""><a href="https://store.voltera.io/products/aci-sc1502-2ml-cartridge" id="">Stretchable carbon ink SC1502</a>: An ink optimized for demanding applications such as <a href="https://www.voltera.io/use-cases/applications/wearables" id="">wearables</a>, offering flexibility under strain</li><li id="">Fine feature printing: 20 μm traces (comparable to etched copper) for transparent metal meshes are achievable</li><li id="">Environmental edge: The Alchemy line reduces reliance on copper etching, slashing toxic waste, and enabling eco-friendly additive manufacturing</li></ul><p id="">Andy also introduced a circuit with fine traces printed with ACI’s FS0117 Semi-Sintering Ink on <a href="https://www.voltera.io/nova" id="">Voltera’s NOVA materials dispensing system</a> to accommodate the world’s smallest 555 timer.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67d445b94c6b42259bd6697b_printing-electronics-flexible-inks-fine-traces.webp" loading="lazy" alt="An image showing fine traces printed with ACI semi-sintering ink using Voltera’s NOVA materials dispensing system" width="auto" height="auto" id=""></div><figcaption id="">Fine traces printed by NOVA</figcaption></figure><h3 id="">Live demonstration: Printing stretchable inks with NOVA</h3><p id="">Nathan demonstrated printing ACI’s stretchable carbon ink SC1502 on <a href="https://store.voltera.io/products/pet-5-sheets?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=pet" id="">PET</a> using a <a href="https://store.voltera.io/products/nordson-efd-7018395-dispensing-tip-27-gauge-clear-1-4-50-box?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=nordson-dispensing-tip" id="">Nordson EFD 7018395 200 μm dispensing tip</a> on NOVA.&nbsp;</p><p id="">The process included:</p><ol id=""><li id="">Probing: NOVA probed the PET substrate and created a height map to ensure precise ink deposition.</li><li id="">Adjusting print settings: Nathan adjusted trace width, print height, and temperature for uniform traces.</li><li id="">Calibrating the ink: NOVA printed the calibration pattern, taking a picture with the built-in camera and guiding Nathan to improve the print results</li></ol><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67d445eb5881814723e8962e_printing-electronics-flexible-inks-probing-pet.webp" loading="lazy" alt="An image showing NOVA probing the PET substrate to create a height map" width="auto" height="auto" id=""></div><figcaption id="">NOVA probing the height of the PET substrate</figcaption></figure><h3 id="">Q&amp;A&nbsp;</h3><p id="">The webinar wrapped up with a Q&amp;A session where participants asked about multilayer printing, curing conditions, conductivity, and material compatibility. Key insights included:</p><ul id=""><li id="">Current handling: Alchemy traces support 1–2 amps for bus lines and about 0.5 amps for wearables (e.g., 40mm × 7mm traces).</li><li id="">High-frequency circuits: Smooth topography and high conductivity make Alchemy inks ideal for <a href="https://www.voltera.io/use-cases/applications/printed-antennas?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=antenna-applications" id="">antenna applications</a>.</li><li id="">Curing and development: Developmental inks cure at 120°C (2–3 minutes in ovens), with ongoing R&amp;D to boost conductivity at lower temperatures.</li><li id="">Ink compatibility: NOVA handles viscosities from 1,000 to 1,000,000 cPs. For custom inks, we recommend prioritizing consistent particle size to avoid nozzle clogs.</li></ul><h2 id="">Additional resources</h2><p id="">Want to learn more about flexible inks and projects completed using flexible inks? Check out these resources:</p><ul id=""><li id="">Blog: <a href="https://www.voltera.io/blog/ultimate-guide-choosing-materials-new-electronics-product?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=ultimate-guide-choosing-material" id="">The Ultimate Guide to Choosing Materials for a New Electronics Product</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/ask-an-expert-conductive-ink-challenges-misconceptions-and-more-with-mike?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=talking-ink-mike" id="">Ask an Expert: Talking Conductive Ink with Mike Mastropeitro from ACI</a></li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-flexible-pcb-silver-ink-pet?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=printing-flexible-pcb" id="">Printing a Flexible PCB with Silver Ink on PET</a> (stretchable insulator)</li><li id="">White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-silver-conductive-ink-cotton-fabric?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=webinar-recap-printing-electronics-flexible-inks&utm_content=printing-cotton" id="">Printing Silver Conductive Ink on Cotton Fabric</a> (stretchable heating ink)</li></ul><p id="">Looking to print flexible electronics with flexible inks? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Demo%20Webinar&utm_source=website&utm_medium=%2Fwebinar-recap-printing-electronics-flexible-inks&utm_content=book-a-meeting" id="">Book a meeting</a> to learn more about NOVA.</p>

Webinar Recap: Printing Electronics with Flexible Inks

In this webinar, we invited ACI Materials to discuss NOVA’s compatibility with flexible inks to create eco-friendly, high-conductivity flexible circuits.

<p id="">The printed electronics landscape has seen substantial growth in recent years and there’s no sign of it slowing down. In 2023, the global printed electronics market size by material and substrate reached <a href="https://market.us/report/printed-electronics-market/" target="_blank">13.1 billion</a> USD. The healthcare/wellness and automotive sectors <a href="https://www.idtechex.com/en/research-report/flexible-and-printed-electronics-2023-2033-forecasts-technologies-markets/943" target="_blank" id="">dominated the market</a>, fueled by various applications ranging from in-mold touch sensing to wearable glucose test strips.&nbsp;</p><p id="">As 2024 kicks off, the forecast for the printed electronics market is showing promising growth — supporting well established sectors like conductive inks while also shining light on emerging use cases like <a href="https://www.voltera.io/blog/in-mold-electronics">in-mold electronics</a>. These trends serve as an indicator of how closely the next generation of electronics will integrate with our daily lives.</p><p id="">Let's take a closer look at where the market is headed.</p><h2 id="">Printed electronics market size</h2><p id="">According to <a href="https://www.startus-insights.com/innovators-guide/electronics-manufacturing-trends/" target="_blank" id="">StartUs Insights</a> printed electronics is forecasted to rank as the sixth most impactful trend in electronics manufacturing in 2024.</p><p id="">Individually, the market for printed electronics is projected to grow at a compound annual growth rate (CAGR) of approximately <a href="https://market.us/report/printed-electronics-market/" target="_blank" id="">19% between 2024 and 2033</a>. By the end of 2024, the market is projected to reach a total value of over 15 billion USD.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be68b263342bd62767433d_66704635d15051aaa15e4ca3_2024-trends-printed-electronics-global-market-size.webp" loading="lazy" alt="Graph showing the global printed electronics market from 2022-2029" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://greyviews.com/reports/printed-electronics-market/62" target="_blank" id="">GreyViews</a></figcaption></figure><h2 id="">What are the market drivers in printed electronics?</h2><p id="">A number of market drivers contribute to the predicted growth rate of printed electronics. These include:&nbsp;</p><ul id=""><li id=""><a href="https://www.voltera.io/blog/role-conductive-inks-additive-electronics-manufacturing" id=""><strong id="">Conductive inks</strong></a><strong id="">:</strong> Being the most critical component of printed electronics applications, continued investment in conductive inks will enable cost-effective production of lightweight and <a href="https://www.voltera.io/blog/flexible-hybrid-electronics" id="">flexible electronics</a>.</li><li id=""><strong id="">Substrates: </strong>Equally as important as conductive inks, the rise in lightweight, flexible, and stretchable applications will also result in increased demand for materials to print on.</li><li id=""><a href="https://www.voltera.io/blog/copper-rfid-tag" id=""><strong id="">RFID technology</strong></a><strong id="">:</strong> As retail tracking and data communication continues to expand, RFID technology will grow in tandem, particularly with regards to opportunities in smart packaging. <a href="https://www.grandviewresearch.com/industry-analysis/printed-electronics-market" target="_blank" id="">Grand View Research</a> expects this technology to realize the fastest CAGR from 2022 to 2030.</li><li id=""><strong id="">The Internet of things (IoT): </strong><a href="https://www.forbes.com/sites/bernardmarr/2023/10/19/2024-iot-and-smart-device-trends-what-you-need-to-know-for-the-future/?sh=7cec41e97f34" target="_blank" id="">Forbes</a><strong id=""> </strong>projected that<strong id=""> </strong>by the end of 2024, over 200 billion IoT devices, ranging from toys to appliances, will be connected online. With the form factors of electronics rapidly evolving, it’s expected that IoT devices will help drive global adoption of printed electronics.</li><li id=""><strong id="">Flexible and stretchable electronics:</strong></li><li id=""><a href="https://www.voltera.io/use-cases/applications/electroluminescent-displays"><strong id="">Displays:</strong></a> With applications in consumer electronics and automotive dashboards, displays hold the highest market share at <a href="https://market.us/report/printed-electronics-market/" target="_blank" id="">over 38%</a>.</li><li id=""><strong id="">Sensors: </strong>Innovations in healthcare, environmental monitoring, industrial automation, and wearables can be attributed to the continued growth of sensors.</li><li id=""><strong id="">Photovoltaics (PV)</strong>: Within the energy sector, flexible PVs are predicted to gain large traction primarily driven by integration with buildings.</li></ul><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be68b263342bd627674346_6670467d219a72391a792ee4_2024-trends-printed-electronics-market-drivers.webp" loading="lazy" alt="A graph showing the global printed electronics market from 2024-2033" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://market.us/report/printed-electronics-market/" target="_blank" id="">Market.US</a></figcaption></figure><p id="">We can clearly see the dominance of conductive inks in printed electronics displayed in this data. Flexible substrates, though not as dominant as conductive inks, are still projecting growth in the global market up to 2033.</p><h2 id="">Where is the largest market for printed electronics?</h2><p id="">According to <a href="https://market.us/report/printed-electronics-market/" target="_blank" id="">Market.US</a>, who analyzes the regional trends and market drivers that make up this industry’s global landscape, the largest markets for printed electronics are:</p><ul id=""><li id=""><strong id="">Asia-Pacific (APAC): </strong>This region represents the largest market for printed electronics adoption. This can be attributed to a robust electronics manufacturing hub created by key market players like <a href="https://www.samsungdisplay.com/eng/index.jsp" target="_blank" id="">Samsung Display</a>, <a href="https://www.lgdisplay.com/eng" target="_blank" id="">LG Display CO. Ltd</a>., and <a href="https://www.eink.com/" target="_blank" id="">E Ink Holdings</a>. Furthermore, the APAC region’s economic growth in major countries like China, Japan, and South Korea, fuels investment in the printed electronics sector.&nbsp;</li><li id=""><strong id="">North America:</strong> Shortly behind APAC comes North America. Their demand for printed electronics primarily focuses on research and development in sectors like healthcare, aerospace, and defense. Some key market players in this region include <a href="https://www.nextflex.us/" target="_blank" id="">NextFlex</a>, <a href="https://flex.com/" target="_blank" id="">Flex Ltd</a>, and <a href="https://www.molex.com/en-us/home" target="_blank" id="">Molex LLC</a>.</li><li id=""><strong id="">Europe:</strong> Renowned for innovation and sustainability, European countries like Germany are projected to continue increasing research and development in advanced consumer electronics and automotive displays, due to the demand for electric vehicles and eco-friendly electronics.</li><li id=""><strong id="">South America:</strong> A smaller market, countries like Brazil and Mexico are fueled by a younger demographic's interest towards technology and innovation.</li><li id=""><strong id="">Middle East and Africa:</strong> The smallest market, this region mainly focuses on technological infrastructure and educational advancement.</li></ul><h2 id="">Printed electronics technology</h2><p id="">In the same report mentioned above by <a href="https://www.grandviewresearch.com/industry-analysis/printed-electronics-market" target="_blank" id="">Grand View Research</a>, this following graph segments the printed electronics market by technology.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66be68b263342bd62767432f_667046d1f45369d2657e0f11_2024-trends-printed-electronics-technology.webp" loading="lazy" alt="A graph showing the global printed electronics market in 2021 with screen printing taking the largest share" width="auto" height="auto" id=""></div><figcaption id="">Image: <a href="https://www.grandviewresearch.com/industry-analysis/printed-electronics-market" target="_blank" id="">Grand View Research</a></figcaption></figure><p id=""><a href="https://www.voltera.io/blog/introduction-screen-printing" id="">Screen printing</a> represents the largest share of the market by technology, holding over 64% of total revenue. <a href="https://www.voltera.io/blog/introduction-inkjet-technology" id="">Inkjet</a> is close behind, followed by flexographic and <a href="https://www.voltera.io/blog/introduction-to-gravure-printing-technology" id="">gravure</a> printing technology. While not listed, <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology" id="">direct ink write dispensing</a> is gaining momentum in the industry for its affordability, accuracy, and low cleaning requirements.</p><h2 id="">Conclusion</h2><p id="">These factors serve as a general indicator of where the printed electronics market is headed for 2024 and beyond. However, the industry’s potential isn’t limited to only a few trends. Whether it’s the digital dashboards transforming automobile interior design, or cellular smart labels revolutionizing shipment tracking for both sender and receiver, these trends will inspire confidence for industry innovators worldwide.</p>

2024 Trends in Printed Electronics

Explore printed electronics trends expected to emerge or grow in 2024. This article covers the industry’s projected growth, market drivers, regional trends, and printing technology.

<p id="">Precision fluid dispensers play a crucial role in manufacturing the products we interact with regularly. They are used in a wide range of industries, so much so, we often forget their role in our everyday lives.</p><p id="">In this article, we will provide a brief overview of fluid dispensing systems, highlight their applications, discuss common challenges with the technology, and share an overview of <a href="https://www.voltera.io/products/nova" id="">NOVA</a>, our materials dispensing system.&nbsp;</p><h2 id="">What are precision fluid dispensing systems?</h2><p id="">Precision fluid dispensing systems allow users to deposit micro amounts of assembly fluids onto a substrate in targeted areas. When dealing in microlitres or nanolitres, the amount of fluid deposited is often nearly impossible to control with most manual pumps and flowmeters. These systems were developed to implement control, precision, accuracy, and consistency in applications requiring microdispensing.</p><p id="">The two most common types of systems for fluid dispensing are:&nbsp;</p><h4 id="">Non-contact&nbsp;</h4><p id="">Also known as jet dispensing or jetting. In a jetting system, the fluid is deposited or “jetted” onto the substrate from a distance.&nbsp;</p><h4 id="">Contact&nbsp;</h4><p id="">This method uses a valve to deposit material in a highly controlled manner. It offers compatibility with a wider range of fluids compared to non-contact systems. Some examples of contact systems include:</p><ul id=""><li><strong id="">Pneumatic/time pressure</strong>: Pulses of air engage the top of the plunger in a specific pattern, driving the plunger forward in the syringe and depositing material.</li><li><strong id="">Mechanical positive displacement</strong>: A rod or piston that forces fluid out of the cartridge.</li><li><strong id="">Auger</strong>: A motor enables the auger screw to rotate, pulling material from the reservoir and guiding it towards the nozzle.</li><li><strong id="">Progressive cavity (PC) pump</strong>: Similar to an auger system, PC pumps utilize a rotor and stator to fill tightly sealed cavities with precise amounts of fluid which are then pushed towards the nozzle, enabling larger consistent deposits with high viscosity fluids.</li></ul><h3 id="">Fluid dispensing applications</h3><p id="">Numerous industries utilize dispensing systems for depositing materials, such as:</p><ul id=""><li>Electronics: <a href="https://www.voltera.io/blog/what-is-solder-paste" id="">Solder pastes</a>, conductive adhesives, <a href="https://www.voltera.io/blog/role-conductive-inks-additive-electronics-manufacturing" id="">conductive inks</a>, flux, coatings, underfill adhesives, and dam and fill.&nbsp;</li><li>Medical: <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="">Biomarker detection</a>, and in- and on-body <a href="https://www.voltera.io/blog/printed-tattoo-electrodes" id="">biomedical sensors</a>.&nbsp;</li><li><a href="https://www.voltera.io/blog/copper-rfid-tag" id="">RFID</a>: Eco-friendly and cost effective non-contact data transfer and localization systems.</li></ul><p id="">Recent <a href="https://www.precedenceresearch.com/fluid-dispensing-systems-market" id="">research</a> indicates the electrical and electronics assembly segment was the leading global market for fluid dispensing equipment in 2024.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6824a6de43f1ffa35b392ab0_precision-fluid-dispensing-system-market-share.webp" loading="lazy" alt="A graph of the fluid dispensing systems market share, by application, 2024. From left to right: electrical and electronics assembly (36%), automotive (29%), medical devices (20%), construction (10%), and others (5%)."></div><figcaption>Fluid dispensing systems market share, by application in 2024. Source: <a href="https://www.precedenceresearch.com/fluid-dispensing-systems-market">Precedence Research</a></figcaption></figure><h3 id="">Materials used in fluid dispensing&nbsp;</h3><p id="">Precision fluid dispensers enable a diverse range of <a href="https://www.voltera.io/blog/compatibility-guide-inks-substrates" id="">material compatibility</a>. Some of the most common materials used in these systems are:</p><ul id=""><li id=""><strong id="">Flux: </strong>A chemical compound used in preparing metal surfaces for soldering.&nbsp;</li><li id=""><strong id="">Conductive ink:</strong> Printable materials that are capable of conducting electricity.&nbsp;</li><li id=""><strong id="">Lubricant:</strong> Oily materials that help reduce friction in surfaces that contact each other.&nbsp;</li><li id=""><strong id="">Solder paste:</strong> Powdered metal solder that is suspended in flux.&nbsp;&nbsp;</li><li id=""><strong id="">Adhesive: </strong>Substances that are capable of<strong id=""> </strong>holding at least two surfaces together permanently.</li><li id=""><strong id="">Sealants:</strong> Materials that attach at least two surfaces together, filling the space between them.</li><li id=""><strong id="">Conformal coatings:</strong> A film applied over components that provides protection against contaminants and environmental factors.</li><li id=""><strong id="">Epoxy underfill: </strong>An epoxy-material used in PCBs to connect a chip to the board through capillary action.</li></ul><p id="">In the same research report referenced above, the graph below shows the growth of fluid dispensing systems of various materials in the global market.</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6824a7182f16b031a170df7a_precision-fluid-dispensing-system-global-market.webp" loading="lazy" alt="A chart showing the fluid dispensing systems market share, by application in 2024. From biggest to smallest: Asia Pacific (46%), North America (29%), Europe (20%), Latin America (10%), MEA (5%)"></div><figcaption>Fluid dispensing systems market share, by region, 2024. Source: <a href="https://www.precedenceresearch.com/fluid-dispensing-systems-market" id="">Precedence Research</a></figcaption></figure><p id="">Though the Asia-Pacific region accounted for 46% of the global revenue for fluid dispensing equipment in 2024, the global demand is projected to increase for systems that are compatible with lubricant, solder paste, adhesives, and sealants. This is primarily driven by advancements in electronics and automotive manufacturing [1].</p><h2 id="">Benefits of precision fluid dispensing&nbsp;</h2><p id="">The primary benefit of precision fluid dispensers is the ability to print high-resolution patterns and features quickly. They are designed to implement control methods to ensure high quality results are achieved. Many applications developed using these systems require consistent prints in high volume orders, so repeatability is key.</p><p id="">These systems can also be integrated into production lines to significantly reduce development time. They offer customizable features like interchangeable dispensers and programmable settings. Swappable dispensers allow users to disperse different types of material that would otherwise take longer to complete using manual processes, or even require a different tool altogether. A user can switch from a precision nozzle designed for depositing an adhesive ink, to a nozzle designed for spraying a coating in a matter of seconds.</p><h2 id="">Challenges with precision dispensing systems</h2><p id="">One of the primary challenges that exists is finding the right system for your application. Unless you’re a material scientist, it is easy to become overwhelmed by technical specifications, even if you know your application’s requirements. There is no one-size-fits-all materials dispensing system on the market; each has its own advantages and disadvantages, most often tailored to specific applications. Even after settling on a system to purchase, it's extremely common to face difficulties with material reliability and flow.</p><p id="">Let’s say you have your system, the material, and a substrate. How do you tell the system where to deposit the fluid? How much should it deposit? When and where should it start and stop?&nbsp;</p><p id="">Balancing these aspects while also adjusting settings to manage consistency, material leakage, and quality results, is often no easy task — especially without an intuitive user interface.</p><h2 id="">NOVA: Voltera’s precision fluid dispensing system</h2><p id=""><a href="https://www.voltera.io/products/nova" id="">NOVA</a> is a precision materials dispensing system that dispenses screen-printable materials (1,000 to 1,000,000 cP) on flexible, stretchable, conformable, and biocompatible materials, as well as rigid substrates. It is ideal for:</p><ul id=""><li>Flexible hybrid electronics R&amp;D</li><li>Novel materials research</li><li>Precise material dispensing</li><li>Seamless transition to mass production</li></ul><p id="">In 2025, we released <a href="https://www.voltera.io/blog/print-multilayer-flexible-stretchable-circuits-nova" id="">Plan</a>, a software feature that enables multilayer printing and print job editing for NOVA, further improving user experience for printing multi-material and multilayer circuit designs.&nbsp;</p><h3 id="">Benefits of NOVA</h3><ul id=""><li>Achieve repeatable results with close-loop pressure feedback, temp-controlled dispensing, and an optimized algorithm for multilayer printing.</li><li>Stack up to four layers of materials and visualize multilayer print sequences before execution.</li><li>Experiment with a wide range of printable materials, from conductive inks and adhesives to solder paste on both flexible and rigid substrates.</li><li>Change designs on the fly and iterate without screens or stencils, eliminating delays and reducing costs while prototyping in-house.</li><li>…and more</li></ul><p id="">For technical specifications of NOVA, <a href="https://www.voltera.io/technical-specifications" id="">click here</a>.&nbsp;</p><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6824a7a66bae719bafe5740e_precision-fluid-dispensing-system-nova-carbon.webp" loading="lazy" alt=" NOVA is printing a potentiometer circuit using functional carbon ink, Voltera Conductor 3 silver ink, and ACI FS0142 flexible silver ink on a polyethylene terephthalate (PET) substrate"></div><figcaption>NOVA printing a functional carbon ink developed by Voltera’s Applications team on <a href="https://store.voltera.io/products/pet-5-sheets" id="">PET</a> sheet</figcaption></figure><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6824a7e2eb0941c0b3792081_precision-fluid-dispensing-system-nova-stretchable.webp" loading="lazy" alt="NOVA is printing a heating element pattern made up of meander lines that resemble a hand using the ACI SH5025 printed fixed resistance heater ink on cotton fabric"></div><figcaption>NOVA printing the ACI SH5025 printed fixed resistance heater ink on cotton fabric</figcaption></figure><figure class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6824a801659d73890470e99d_precision-fluid-dispensing-system-nova-gold.webp" loading="lazy" alt="NOVA printing ECG electrodes shaped like hexagonal labyrinths using Creative Materials’ EXP 2613-40 biocompatible gold ink and Celanese’s Intexar PE874 silver ink on thermoplastic polyurethane (TPU) substrate"></div><figcaption>NOVA printing Creative Materials’ EXP 2613-40 biocompatible gold ink on <a href="https://store.voltera.io/products/intexar-tpu-5-sheets" id="">TPU</a> to make ECG electrodes</figcaption></figure><h2 id="">Conclusion</h2><p id="">As additive manufacturing continues to revolutionize research outcomes and product development, innovators are searching for the right solution to meet their goals. They’re looking to accelerate development timelines and find cost effective methods for achieving reliable, high quality results.</p><p id="">If you would like to see if <a href="https://www.voltera.io/products/nova" id="">NOVA</a> is a fit for your application, <a href="https://meetings.hubspot.com/royperez/v-one-or-nova-demo?__hstc=13863464.f4bac85f003ca4e96b9dc2632e0f0baa.1698168973705.1701183200004.1701198740111.109&__hssc=13863464.3.1701198740111&__hsfp=1999393944" id="">book a meeting</a> with one of our application specialists.&nbsp;</p><h2 id="">References</h2><p id="">[1] Precedent Research, <a href="https://www.precedenceresearch.com/fluid-dispensing-systems-market" id="">Fluid Dispensing Systems Market Size, Share, and Trends 2025 to 2034</a>, 2025.</p>

What Are Precision Fluid Dispensing Systems? 

Learn how precision fluid dispensing systems are changing additive electronics. Explore their benefits, materials, challenges, and where Voltera’s NOVA system fits in.

What are Precision Fluid Dispensing Systems? 

<p id="">In this webinar, Voltera's Support Lead, <a href="https://ca.linkedin.com/in/nathanshinkar" id="">Nathan Shinkar</a>, and Panasonic's Business Director, <a href="https://www.linkedin.com/in/andybehr" id="">Andy Behr</a>, explored the capabilities of <a href="https://na.industrial.panasonic.com/products/electronic-materials/printed-and-flexible-hybrid-materials/lineup/beyolex-stretchable-circuit-materials/series/144592" id="">BEYOLEX™ high-temperature stretchable film</a>, a groundbreaking substrate designed for soft circuit applications.&nbsp;</p><p id="">The session provided an in-depth look at BEYOLEX's unique properties and a live demonstration of printing a force-sensitive resistor (FSR) using <a href="https://www.voltera.io/nova" id="">NOVA</a> and <a href="https://store.voltera.io/products/aci-ss1109-2ml-cartridge?srsltid=AfmBOor9orMYVz2nygWbpSlawy40hsk0MnVp5nIIdByx6pKKRf-8vQ5U" id="">ACI SS1109 stretchable silver ink</a>.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=gyICoRTERFI&list=PLbZdiubRTqoqS9CDbZrtc5kbc-bhfKdUw"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/gyICoRTERFI" title="Webinar: Printing on BEYOLEX™ High-Temperature Stretchable Film with NOVA"></iframe></div></figure><h2 id="">Webinar highlights&nbsp;</h2><h3 id="">Introduction to BEYOLEX™</h3><p id="">Andy Behr introduced BEYOLEX™, Panasonic's innovative high-temperature stretchable film, emphasizing its advantages over traditional substrates such as TPU and silicone. BEYOLEX stands out due to its:</p><ul id=""><li id="">High elongation (200%) with near-zero hysteresis, meaning it can stretch and return to its original shape without deformation.</li><li id="">Exceptional heat resistance, withstanding temperatures over 300°C, making it ideal for applications that require soldering or exposure to high temperatures.</li><li id="">Superior durability, retaining mechanical properties even after prolonged exposure to extreme environments.</li></ul><p id="">Andy also discussed various potential applications of BEYOLEX, including wearables, robotics, flexible heaters, and sensor patches, highlighting its versatility in printed electronics.</p><h3 id="">Printing demonstration with NOVA</h3><p id="">Following the introduction, Nathan conducted a live printing demonstration using the NOVA modular dispensing system. The session covered key steps in the process, including:</p><ol id=""><li id="">Preparing the substrate: BEYOLEX was mounted onto the NOVA vacuum module to ensure a stable print surface.</li><li id="">Loading the materials: ACI’s SS19 stretchable silver ink was selected due to its compatibility with BEYOLEX's stretchability and temperature resistance.</li><li id="">Printing with NOVA: Nathan showcased how NOVA’s intelligent software and precise dispensing capabilities produced fine conductive traces with high accuracy. The process included print file alignment, height mapping using NOVA’s smart probe, and the final printing step.</li><li id="">Post-processing: The printed circuit was cured at 135°C for 5 minutes, well below BEYOLEX's threshold, ensuring proper conductivity and flexibility.</li></ol><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/679bf49f0b247dfa4ab2a3b7_679bf4652856fb23add81aa1_webinar-recap-beyolex-printed-sensors-stretched.webp" loading="lazy" alt="The sensors being stretched" width="auto" height="auto" id=""></div><figcaption id="">The sensors being stretched</figcaption></figure><h2 id="">Additional resources</h2><p id="">Curious what other projects can be done using stretchable substrates like BEYOLEX™? Check out these resources:</p><ul id=""><li id="">White papers: <a href="https://www.voltera.io/use-cases/white-papers" id="">Projects done using our dispensing systems</a></li><li id="">Blog: <a href="https://www.voltera.io/blog/compatibility-guide-inks-substrates" id="">A Compatibility Guide for Inks and Substrates</a></li><li id="">Video: <a href="https://youtube.com/playlist?list=PLbZdiubRTqoqS9CDbZrtc5kbc-bhfKdUw&si=TpSbDWjqoyVp_tcQ" id="">Other Voltera webinars on additive electronics</a></li></ul><p id="">Ready to print your soft circuits? <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Blog%20Campaign&utm_source=website&utm_medium=webinar-recap-printing-beyolex&utm_content=book-a-meeting" id="">Book a meeting</a> with us now. To stay informed on upcoming webinars, <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a" id="">subscribe to our newsletter</a>!&nbsp;</p>

Webinar Recap: BEYOLEX™ Stretchable Film for Soft Circuits

In this webinar, we explored Panasonic BEYOLEX™ stretchable film’s properties and printed force-sensitive resistors using ACI’s stretchable silver ink.

<p id="">In our latest webinar, the spotlight was on printing biomedical sensors using <a href="https://www.voltera.io/nova" id="">NOVA technology</a>, a landmark in the evolution of printed electronics. We also highlighted Creative Materials’ <a href="https://server.creativematerials.com/datasheets/DS_124_36.pdf" target="_blank" id="">124-36 Ag/AgCl (silver silver-chloride) ink</a>, which was perfect for the application we demonstrated.</p><h2 id="">Precision materials dispensing&nbsp;</h2><p id="">The webinar focused primarily on the precision and adaptability of NOVA in printing biomedical sensors. With the use of advanced materials and sophisticated printing techniques, made easier with products like NOVA and Creative Materials inks, you’re able to create sensors that are both highly functional and biocompatible.</p><h2 id="">Webinar highlights</h2><p id=""><strong id="">Printing techniques explored:</strong> We discussed various methods like syringe dispensing and screen printing, emphasizing their relevance in biomedical applications.</p><p id=""><strong id="">Material compatibility:</strong> The webinar highlighted the compatibility of NOVA with a range of materials, including innovative silver/silver-chloride inks.</p><p id=""><strong id="">Flexibility:</strong> Customization became a key theme, with discussions in the live chat of the webinar on tailoring sensor designs to specific biomedical needs and the flexibility of materials on different substrates.</p><p id=""><em id="">Interested in exploring NOVA's capabilities for your biomedical projects?&nbsp;</em><a href="https://meetings.hubspot.com/royperez/meet-with-team-voltera" id=""><em id="">Get in touch</em></a><em id=""> with our experts for a personalized demo or more information.</em></p><h2 id="">Audience Q&amp;A insights</h2><p id=""><strong id="">Ink selection:</strong> One question inquired on the difference between pure silver inks and silver/silver-chloride inks. Our experts explained that while pure silver offers higher conductivity, silver/silver-chloride inks provide greater biocompatibility, crucial for sensors in direct contact with skin.</p><p id=""><strong id="">Printing on flexible materials:</strong> A question arose about NOVA's ability to print on flexible substrates and we clarified that NOVA's precision and pressure feedback dispensing make it ideal for such applications, above and beyond the capability of the <a href="https://www.voltera.io/v-one" id="">V-One</a>.</p><p id=""><strong id="">Ink preparation and handling:</strong> Questions about ink preparation underscored the importance of proper material handling for optimal printing results. Many helpful tools and techniques were highlighted, including but not limited to:&nbsp;</p><ul id=""><li id="">A planetary mixer to help blend materials to ensure a complete mix and consistent flow.</li><li id="">Deflection testing to identify whether there’s air in the dispenser, which is further helped by the pressure feedback from NOVA’s Smart Dispenser.</li><li id="">Consultation with experts (like <a href="https://www.creativematerials.com" target="_blank" id="">Creative Materials</a>) for recommendations when you’re looking to create custom mixed materials for your application.</li></ul><h2 id="">Practical demonstration</h2><p id="">A significant portion of the webinar was dedicated to a live demonstration, showcasing the printing of a biomedical sensor using NOVA. This hands-on display not only highlighted the machine’s capabilities but also addressed practical considerations like setup time and material preparation.</p><p id=""><em id="">Didn’t make it to the webinar? Watch it here:</em></p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/dcr2Itxfbq4?feature=shared"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/dcr2Itxfbq4" title=""></iframe></div></figure><h2 id="">Applications and future of printed electronics in a biomedical setting&nbsp;</h2><p id="">We discussed the wide range of applications for <a href="https://www.voltera.io/use-cases/applications/bioelectronics">printed biomedical sensors</a>, from ECG/EKG and EEG sensors to more novel uses in drug delivery systems and comfortable, <a href="https://www.voltera.io/use-cases/applications/wearables">wearable health monitors</a>. The session also touched upon future trends and potential advancements in this rapidly evolving field.</p><p id="">Special thanks to everyone who participated in the chat. There were tons of questions about the capabilities of NOVA and Creative Materials inks. The most common themes were the importance of precision in dispensing, versatility in materials, and customization for creating advanced medical devices.</p><p id="">To stay informed on future webinars, <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a?__hstc=13863464.a6e861abd69863d5e355c083710f6ae2.1708615212577.1725990309429.1725995530379.319&__hssc=13863464.9.1725995530379&__hsfp=141023726" id="">subscribe to our newsletter</a>.</p>

Webinar Recap: Printing Biomedical Sensors with Ag/AgCl ink

A summary of Voltera's printed electronics webinar, including techniques and materials that are compatible with biomedical applications.

A recap of our webinar on biomedical sensors printed with silver silver-chloride ink using NOVA.

<p id="">In a future characterized by flexibility, stretchability, sustainability, and affordability, conductive inks serve as tools to foster electronics innovation. In this blog, we will explore the role of conductive inks in today’s printed electronics landscape.</p><h2 id="">What are conductive inks?</h2><p id="">Conductive inks are printable materials that are capable of conducting electricity. These inks contain conductive particles or flakes such as silver, copper, and carbon, and enable electrical conduction. Most inks aren’t conductive right from the beginning — they need to be processed to evaporate the solvents which strengthens the connection between the metal particles. After printing, they are cured in different ways to render them electrically conductive. Typically, the main curing process we use on <a href="https://www.voltera.io/v-one" id="">V-One</a> for low temperature inks is thermal curing. This process applies heat to initiate polymerization, solidifying the ink and changing the volume of the traces. However, there are alternative methods for processing conductive inks, such as ultraviolet (UV) curing. UV curing exposes the uncured ink to UV light, converting the monomers to polymers which hardens the liquid.</p><p id="">To learn more about what conductive inks are made of, see <a href="https://www.voltera.io/blog/what-is-printed-electronics-conductive-inks">What is Printed Electronics? Conductive Inks.</a></p><h2 id="">Advantages of conductive inks in additive manufacturing:</h2><p id="">The <a href="https://www.precedenceresearch.com/flexible-electronics-market#:~:text=The%20global%20flexible%20electronics%20market%20is%20poised%20to%20grow%20at,USD%2071.54%20billion%20by%202032." target="_blank" id="">increasing demand</a> for flexible and stretchable electronic devices requires conductive materials that can satisfy the characteristics of the devices. Traditionally, subtractive manufacturing processes like chemical etching, require an extensive production process that is costly, wastes material, and is environmentally harmful. Conversely, conductive inks are used in additive manufacturing processes — providing an extensive list of benefits to users:</p><h3 id="">Testing and design acceleration</h3><p id="">Because conductive inks are additive in nature:</p><ul id=""><li id="">They accelerate the design and iteration stage for developing electronics.&nbsp;</li><li id="">They avoid multi-step procedures related to chemically stripping materials (keep reading — there’s more on this process below.&nbsp;</li></ul><p id="">Instead, they utilize a more streamlined process of printing only what’s needed where it is needed. This approach eliminates material waste and enables users to develop and test their prototypes faster.</p><h3 id="">Material versatility of conductive inks</h3><p id="">Conductive inks are comprised of a wide variety of materials, providing users with a diverse range of application compatibility. With various resistance thresholds and temperature ranges, conductive inks allow for compatibility with <a href="https://www.voltera.io/blog/flexible-hybrid-electronics" id="">flexible</a> and stretchable applications, on a wide variety of films and substrates. Here are a few examples of the inks and their potential applications:</p><ul id=""><li id=""><strong id="">Silver</strong> <strong id="">conductive inks</strong> are easy to print and offer excellent conductivity and low resistance, making them ideal for applications requiring high flexibility. Typical applications where silver conductive inks are used include aerospace electronics, alternative<a href="https://www.voltera.io/use-cases/applications/printed-batteries"> energy solutions</a>, <a href="https://www.voltera.io/use-cases/applications/bioelectronics">biosensors</a>, <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper">RFID tags</a>, and automotive sensors.</li><li id=""><strong id="">Silver/silver chloride (Ag/AgCl) inks </strong>are an environmentally friendly option, commonly used in biomedical electronics. Their smooth finish and ability to achieve different resistance and sensitivity levels by adjusting their ratio, makes them specifically suitable for on or in-body applications like <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">health monitoring patches and sensors</a>.</li><li id=""><strong id="">Carbon inks</strong> offer high thermal stability at a lower cost compared to silver conductive inks. Their chemical inertness makes carbon inks suitable for printing resistors and conductors on non-conductive materials such as plastics, ceramics, and paper. Carbon-based inks are useful for applications like windshield defrosters, resistors, <a href="https://www.voltera.io/use-cases/white-papers/printing-multilayer-flexible-membrane-keyboard-conductive-silver-ink-dielectric-ink-pet">computer keyboards</a>, and capacitive sensors where conductivity and stability are required.&nbsp;</li><li id=""><strong id="">Gold</strong> <strong id="">and platinum</strong> <strong id="">conductive inks</strong> offer very high conductivity and longevity, and are used in applications where the higher conductivity can justify the high price. These conductive inks durability can be attributed to their resistance to corrosion and oxidation. Some common applications where gold and platinum conductive inks are used include photovoltaics and thin film transistors.&nbsp;</li></ul><h3 id="">Sustainability and material waste</h3><p id="">Subtractively manufactured electronics involves chemical etching, a process that subjects material to chemicals to remove excess material until the final form is obtained. This process results in significant material waste and also exposes handlers to toxic chemicals such as sodium hydroxide or ferric chloride.&nbsp;</p><p id="">A much safer option is printing conductive inks additively onto a substrate or film in the desired pattern — resulting in no exposure to toxic chemicals or creation of material waste.</p><h2 id="">Applications of conductive inks</h2><p id="">There are numerous applications for conductive inks. We’ve highlighted a few below that been developed on our materials dispensing systems, <a href="https://www.voltera.io/nova" id="">NOVA</a> and <a href="https://www.voltera.io/v-one" id="">V-One</a>:</p><h3 id="">Remote controlled robotic hand with strain gauges</h3><p id="">This project involved designing a remote controlled robotic hand, printed using a highly conductive <strong id="">stretchable silver ink</strong> from <a href="https://materials.celanese.com/gb/products/pdf/SI/Micromax%E2%84%A2%20Intexar%E2%84%A2%20PE874-gb.pdf" target="_blank" id="">Celanese</a>. The process of building a remote controlled robotic hand involved designing strain gauges that could stretch while maintaining conductivity and exhibiting a measurable change in resistance. Using this stretchable conductive ink opens the door for designing strain gauges on nearly any flexible material.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/675a09a54d4089b505c75dd4_667041fdeaa7325a8cf65e6b_Role-conductive-inks-robotic-hand-strain-gauges.webp" loading="lazy" alt="Robot hand and control glove shown side by side" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.voltera.io/blog/building-a-remote-controlled-robotic-hand-with-strain-gauges" id="">See the build process</a></figcaption></figure><h3 id="">Insole pressure sensor&nbsp;</h3><p id="">This application saw the full design and build of an insole with a force sensitive resistor capable of detecting pressure and weight distribution in a shoe. Using the same stretchable silver conductive ink as the robotic glove above, traces were printed onto a sheet of thermoplastic polyurethane (TPU) which then comes into contact with a carbon sheet under pressure — allowing for resistance to increase in various regions of the print.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/675a09a54d4089b505c75dd1_6670424ea43c873f9045b0c1_Role-conductive-inks-insole-pressure-sensor.webp" loading="lazy" alt="Insole pressure sensor laid out on a table, connected to wires" width="auto" height="auto" id=""></div><figcaption id="">Insole pressure sensor</figcaption></figure><h3 id="">Biomedical sensors with silver-silver chloride ink</h3><p id="">Another industry where we continue to see the application of conductive inks flourish is biomedical health monitoring. In our webinar <strong id="">Printing Biomedical Sensors</strong>, we demonstrated printing a biomedical sensor using Creative Materials’ <a href="https://server.creativematerials.com/datasheets/DS_124_36.pdf?utm_source=hs_email&utm_medium=email&_hsenc=p2ANqtz--4FZ7IrgeZBrspF9UgInjiWDGpZ2zkWPzzlX4ld_93xfqFIrVmyoD7KjPSul3O02kAeA2y" target="_blank" id="">124-36 silver-silver chloride</a> on TPU.&nbsp;</p><p id="">Didn’t get a chance to attend the webinar? Watch the&nbsp;recording on our YouTube channel:</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/dcr2Itxfbq4?feature=shared"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/dcr2Itxfbq4" title="Webinar: Printing Biomedical Sensors with NOVA"></iframe></div></figure><h3 id="">RFID Tags with nano copper ink</h3><p id="">Another common application for conductive inks is printing RFID tags. In this example, the tags were printed using Copprint’s <a href="https://www.copprint.com/wp-content/uploads/2021/12/TDS-LF-301-Beta-22-08-21.pdf" target="_blank" id="">LF-301</a> nano copper ink on paper in the desired pattern. This process resulted in better performance than an off-the-shelf tag we purchased from a market volume leader in RFID. With NOVA, we were able to produce one fully printed RFID tag antenna in less than 15 minutes.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/675a09a54d4089b505c75de4_667042c41dcc310945a22cd4_Role-conductive-inks-RFID-nano-copper-ink.webp" loading="lazy" alt="Printing with NOVA: Copper RFID tags on paper" width="auto" height="auto" id=""></div><figcaption id=""><a href="https://www.voltera.io/blog/copper-rfid-tag" id="">See more</a></figcaption></figure><h2 id="">Choosing an ink</h2><p id="">Each ink has its own unique specifications and applications. Making a decision on which ink to choose can seem intimidating, so we are going to help simplify this process for you:</p><p id="">When choosing an ink, there are a few main aspects to consider to ensure your application achieves the results you're looking for. The main consideration is <strong id="">what you're trying to achieve</strong> with your application. This main decision will lead to other secondary considerations such as the substrate you plan to print on, the technology you intend to print with, and your budget. For a detailed breakdown on ink compatibility, see <a href="https://www.voltera.io/blog/compatibility-guide-inks-substrates" id="">A Compatibility Guide for Inks and Substrates</a>.</p><p id="">Some conductive ink suppliers include:</p><ul id=""><li id=""><a href="https://www.acimaterials.com/" target="_blank" id="">ACI Materials</a></li><li id=""><a href="https://www.creativematerials.com/" target="_blank" id="">Creative Materials</a></li><li id=""><a href="https://www.copprint.com/" target="_blank" id="">Copprint</a></li><li id=""><a href="https://www.celanese.com/products/micromax" target="_blank" id="">Celanese</a></li><li id=""><a href="https://www.novacentrix.com/" target="_blank" id="">Novacentrix</a></li></ul><p id="">If you have questions about ink compatibility with our NOVA or V-One dispensing systems, please contact us at <a href="mailto:support@voltera.io" id="">support@voltera.io</a>.&nbsp;</p><h2 id="">Conclusion</h2><p id="">The innovation of technology can’t exist without the innovation of processes. As electronics continue to move into a more flexible, sustainable, affordable, and reliable future, conductive inks serve as tools to make these innovations achievable.&nbsp;</p><p id="">To discuss whether a NOVA or V-One dispensing system might be right for your application, <a href="https://meetings.hubspot.com/royperez/v-one-or-nova-demo" target="_blank" id=""><strong id="">book a meeting</strong></a> with one of our application specialists.</p>

The Role of Conductive Inks in Additive Electronics Manufacturing

Explore the pivotal role conductive inks play in advancing printed electronics. From faster design, to their benefits and applications, discover how these versatile inks continue to revolutionize additive electronics.

Explore the pivotal role conductive inks play in advancing printed electronics. From their design, to their benefits, to their applications, discover how these versatile inks continue to revolutionize additive electronics.

<h2 id="">Nordson EFD nozzles launched</h2><div data-rt-embed-type='true'><a id="nordson-efd-nozzles-launched-anchor">Nordson EFD nozzles launched</a></div><p id="">Voltera is excited to announce that we’ve added Nordson EFD straight barrel nozzles to our <a href="https://store.voltera.io/collections/consumables" id="">online store</a> in four different sizes: 100, 150, 200, 250 μm. These disposable stainless steel nozzles can improve dispensing with lower viscosity fluids and inks on <a href="https://www.voltera.io/v-one" id="">V-One</a> and <a href="https://www.voltera.io/nova" id="">NOVA</a>, but are not recommended for use with solder paste.&nbsp;</p><p id="">Not sure which nozzle you need? Your application and material will dictate which is right for you. For help choosing the correct nozzle, see <a href="https://www.voltera.io/blog/nordson-efd-high-performance-low-cost-nozzles#how-to-choose-a-nozzle-anchor" id="">How to choose a nozzle </a>below.</p><h2 id="">Benefits of Nordson EFD nozzles</h2><div data-rt-embed-type='true'><a id="benefits-of-nordson-efd-nozzles-anchor">Benefits of Nordson EFD nozzles</a></div><p id="">Nozzles (or dispensing tips) direct the flow of material as it exits the cartridge onto your substrate. They are a critical component of the dispensing system and control many aspects of the quality of your output. The Nordson EFD nozzles new to our store offer a wide range of benefits:</p><ul id=""><li id=""><strong id="">Versatile fluid handling</strong>: These nozzles are designed to handle a wide range of assembly fluids.</li><li id=""><strong id="">Precise and consistent depositing</strong>: Their burr-free passivated stainless steel tubing allows for precise and consistent fluid depositing, making these nozzles suitable for lower viscosity materials.</li><li id=""><strong id="">Leak-proof design</strong>: Their polypropylene SafetyLok™ hubs prevent leakage and ensure drip-free dispensing.</li><li id=""><strong id="">Cost-efficiency: At a more economical price point than Subrex nozzles, these will reduce consumable costs while still achieving high quality dispensing.</strong></li></ul><p id="">While we now offer these Nordson EFD nozzles in our store, you can still find other nozzles there as well, including Voltera disposable and Subrex metal nozzles.</p><h3 id="">Voltera disposable nozzles</h3><div data-rt-embed-type='true'><a id="voltera-disposable-nozzles-anchor">Voltera disposable nozzles</a></div><p id="">Disposable nozzles serve a cost effective purpose — minimizing ink volume and maximizing flow. They can also be a suitable option if you find your metal Subrex nozzles are clogging or breaking frequently.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" style="max-width:40%" data-rt-type="image" data-rt-align="center" data-rt-max-width="40%"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66db569ce46d4305fdb13ce3_667040491dcc310945a03cd7_Nordson-EFD-nozzles-Voltera-disposable-nozzles.webp" loading="lazy" alt="Voltera disposable nozzles" width="auto" height="auto" id=""></div><figcaption>Voltera disposable nozzles</figcaption></figure><h3 id="">Subrex precision nozzles</h3><div data-rt-embed-type='true'><a id="subrex-precision-nozzles-anchor">Subrex precision nozzles</a></div><p id="">These precision nozzles provide excellent resolution and more accurate dispensing of ink and solder paste but are more expensive and fragile than other nozzles. The enhanced performance comes from a tapered design and a thinner wall to improve flow performance with high viscosity materials and reduce spread at the target location.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" style="max-width:40%" data-rt-type="image" data-rt-align="center" data-rt-max-width="40%"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66db569ce46d4305fdb13cea_667040938723d8e7d0e94451_Nordson-EFD-nozzles-Subrex-precision-nozzles.webp" loading="lazy" alt="Subrex precision nozzles" width="auto" height="auto" id=""></div><figcaption>Subrex precision nozzles</figcaption></figure><h2 id="">How to choose a nozzle</h2><div data-rt-embed-type='true'><a id="how-to-choose-a-nozzle">How to choose a nozzle</a></div><p id="">This table gives you a brief overview of the types of nozzles we carry as well as their printer and fluid compatibility:</p><p id="">[script]https://uploads-ssl.webflow.com/6334888a34bfac591c6aa6e9/665f130ae3dff8ef7e8c2b7a_Table%20template.txt[/script]</p><p id=""><em id="">* Please note: Nozzles can be used with materials and printers not currently stocked in the Voltera online store.&nbsp;</em></p><p id="">Still not sure which nozzle you need? We’ve put together documentation that will help you choose the right nozzle for your project.&nbsp;</p><h5 id=""><a href="https://docs.voltera.io/nova/learn-more/working-with-custom-inks#choosing-nozzles" id="">How to choose a nozzle</a></h5><p id="">If you have questions about material or nozzle compatibility, we can help! Please contact us at <a href="mailto:hello@voltera.io" id="">hello@voltera.io</a>.</p><h5 id=""><a href="https://store.voltera.io/collections/consumables?filter.p.m.custom.product_type=Nozzles" id="">Shop nozzles</a></h5>

Nordson EFD: High Performance, Low Cost Nozzles

You can now purchase four different Nordson EFD dispensing nozzles directly from the Voltera store. They are compatible with NOVA and V-One platforms, and provide a cost-effective alternative with excellent dispensing performance for conductive inks.

<p id="">In the field of printed electronics, researchers are constantly pushing boundaries to discover novel applications for emerging materials and technologies. The Massachusetts Institute of Technology’s (MIT) <a href="https://ieeexplore.ieee.org/document/10007579" target="_blank" id="">latest research</a> on carbon nanotube field emissions will have lasting impacts in this field, offering vital insights into properties of this material and opening up the opportunity for a wider discussion on its use cases. We're going to synopsize those findings for you; this is a must-read for researchers in printed electronics. </p><p id="">Let's start with the basics.</p><h2 id="">What are carbon nanotubes?</h2><p id="">Colloquially called buckytubes, carbon nanotubes (CNTs) are a hollow, cylindrical structure with a diameter in the nanometer range. Their versatility is what makes them so attractive for research. Their structure can adjust slightly to allow for greater functionalization (by slightly shifting the bonded carbon hexagons) and they have great electronegativity, meaning that they have an easy time bonding with other materials. Their cylindrical structure lends them the ability, via ease of covalent bonding, to combine with other materials in order to augment and enhance them. Their predecessors, buckyballs, did not share the same depth of functionality due to the limits of the ball shape.</p><h2 id=""><strong id="">The power of carbon nanotubes (CNTs)</strong></h2><p id="">Carbon nanotubes have emerged as a significant player in the realm of nanotechnology, owing to their remarkable electrical, thermal, and mechanical properties. Composed of carbon atoms in a cylindrical structure, CNTs are at the forefront of innovations in nanotechnology, enabling advancements in fields such as nanoelectronics, energy storage, and sensing. In this context, space propulsion is a key part of MIT’s research.</p><h2 id=""><strong id="">MIT's pioneering research</strong></h2><p id="">Researchers at MIT’s Velasquez Group have delved into the intricate world of carbon nanotube field emissions, exploring the previously uncharted territories of their potential. Their investigations have focused on understanding the intrinsic properties and behaviors of carbon nanotubes (CNTs) when exposed to external electric fields. Advanced experimentation and comprehensive analysis have enabled the researchers to gain deeper insights into the emission characteristics of CNTs. Their work is shedding light on optimizing the configurations and conditions under which CNTs operate, thereby enhancing their performance and expanding their potential applications in printed electronics.</p><h2 id=""><strong id="">Precision and control: Leveraging NOVA in research</strong></h2><p id="">The Velasquez Group employed <a href="https://www.voltera.io/nova" id="">NOVA</a>, a materials dispensing system which utilizes advanced <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">direct ink writing technology</a> to print detailed structures with extreme precision.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" style="max-width:25%" data-rt-type="image" data-rt-align="center" data-rt-max-width="25%"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6776f822bbde3bc1712aa45d_66703baff8eaacf0224752d5_Carbon-nanotube-field-emitters-device-design.webp" loading="lazy" alt="Spiralized, in-plane gated field emission device design" width="auto" height="auto" id=""></div><figcaption id="">Spiralized, in-plane gated field emission device design. Red trace is copper (extractor electrode), yellow trace is printed CNT ink (emitting electrode). Vias connect to underlying blue traces leading to a card edge connector away from the device.</figcaption></figure><p id="">Concentric spirals of copper and CNT ink were printed <strong id="">with a minimal 15 µm variation</strong> between them.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6776f822bbde3bc1712aa457_66703cacc24b09c1e4486591_Carbon-nanotube-field-emitters-CNT-traces.webp" loading="lazy" alt="Printed CNT traces, a confocal microscope view with overlaid measurement line and profile of measurement line" width="auto" height="auto" id=""></div><figcaption id="">Printed CNT traces. A) Confocal microscope view with overlaid measurement line. B) Profile of measurement line, showing rough copper traces and rounded CNT traces with roughly 15 µm misalignment.</figcaption></figure><p id="">This precision is extraordinary and is not commonly achievable with cleanroom equipment available today. Providing crucial control over surface mapping, optical alignment, and pressure control, NOVA was key in realizing such unprecedented results.<br><br></p><blockquote id=""><em id="">“With NOVA, we can make devices and align them to sub 10 micron precision, which is essential to everything that we do. If we have a 20 micron deviation, our devices explode. So you know, we need a lot of precision, we need to have tuned materials, and NOVA enables both of those.”</em><br></blockquote><blockquote id=""><em id="">- Alex Kashkin, Graduate Researcher, Velásquez Group at MIT</em><br></blockquote><h2 id=""><strong id="">Groundbreaking findings: Emission mechanisms and properties</strong></h2><p id="">The study provides a profound understanding of the emission mechanisms of carbon nanotubes, emphasizing the significance of field enhancement factor (FEF) and emission areas. Researchers have discovered that the emission currents of CNTs are highly dependent on the geometric configuration and alignment of the nanotubes, as well as the applied electric field. By manipulating these variables, it's possible to optimize the emission properties of CNTs to suit various applications in printed electronics.</p><p id="">One of the key highlights of the research is the revelation that the emission currents are highly localized, occurring predominantly at the tips of the nanotubes, which has crucial implications for designing efficient emission sources. This understanding is pivotal for harnessing the full potential of CNTs in developing advanced electronic devices, sensors, and other nanotechnology applications.</p><h2 id=""><strong id="">Possible real-world applications</strong></h2><p id="">The exploration of carbon nanotube field emitters is just the tip of the iceberg. MIT's work is opening up new avenues for research and development in printed electronics. We're optimistic about harnessing the wide range of capabilities that CNTs exhibit to help transform the landscape of nanotechnology and printed electronics.</p><p id="">‍<strong id="">Medical and scientific instruments:</strong> The devices could prove invaluable in miniaturized mass spectrometers, and even in crafting compact x-ray generators.</p><p id="">‍<strong id="">Relaxed vacuum needs:</strong> The compatibility with low-vacuum environments, especially at the 10 mTorr level, synchronizes perfectly with the industry’s move towards easing vacuum preconditions for compact instruments.</p><p id="">‍<strong id="">Radiography and materials analysis:</strong> Envision a handheld x-ray source, adept at material analysis through fluorescent spectroscopy. With the required currents being significantly lesser than the bias voltages essential for x-ray production, the feasibility is undeniable.</p><p id="">‍<strong id="">Nanosatellite electric propulsion: </strong>The CNT fully-printed electron sources can be the go-to for neutralizers in pico and nanosatellite electric propulsion systems. Given their resilience against oxygen traces in low-Earth orbit (LEO), they could find a role in a plethora of nanosatellite missions, ranging from Earth surveillance and communication to weather prediction.</p><h2 id=""><strong id="">Closing thoughts</strong></h2><p id="">MIT’s in-depth research on carbon nanotube field emissions is helping to part the veil on the potential of CNTs in printed electronics. The findings of this study are pivotal for fostering advancements and innovations in nanotechnology. Voltera is proud to play a critical role in unlocking research opportunities, with tools like <a href="https://www.voltera.io/nova" id="">NOVA</a> enabling research advancements through novel printed electronics technologies.&nbsp;</p><p id="">Our goal has always been to empower scientists and researchers to explore new possibilities, promising a future where the applications and implications of printed electronics are bound only by the limits of human imagination. By bridging the gap between research and <a href="https://www.voltera.io/use-cases/applications">real-world applications</a>, we are stepping into a future with potential for groundbreaking discoveries and developments that could impact daily life from the clothes we wear, to revolutionary medical treatments, and the exploration and understanding of space.</p><p id="">Stay tuned for more developments in printed electronics research by <a href="https://share.hsforms.com/1DG3jeG6BRDOZ6o0OGyVv-g34u2a?">subscribing to our newsletter</a>. Want to explore the world of possibilities opened up by cutting-edge, easy-to-use printing platforms? Want to join the conversations happening at the frontier of scientific discovery and innovation in printed electronics? <a href="https://www.voltera.io/contact" id="">Contact us</a>.</p>

Unlocking the Potential of Carbon Nanotube Field Emitters: A Glimpse into MIT's Revolutionary Research

Additively manufactured CNT electron sources on glass substrates via direct ink writing, yielding 120 μA emission currents and enabling cost-effective applications like mass spectrometry and nanosatellite propulsion.

MIT’s Research on Carbon Nanotube Field Emitters in Printed Electronics

Highlighting research from Alex Kashkin and his team at MIT. Explore the design, fabrication, and experimental characterization of the first fully additively manufactured carbon nanotube (CNT) field emission electron sources

<p id="">What if items in a room could "talk" to each other wirelessly — without any configuration, batteries, or contact? What if instead of having to wait in line at the supermarket, you could just checkout by walking out the front door? Or the next time you misplace your keys, they could tell you where they were located? RFID is a technology that can do all this and more.</p><h2 id="">What is RFID?</h2><p id="">Radio Frequency Identification (commonly known as RFID) is a technology that leverages wireless communication over radio waves to both transfer data and locate objects. Many of us use RFID as part of our everyday life without noticing it, whether it be entry keycards, contactless payments, or toll road transponders on vehicles. While RFID has been streamlining processes for decades, there has been an explosion in the <a href="https://www.voltera.io/use-cases/applications/printed-batteries">applications of RFID</a> in recent years.</p><p id="">Retail businesses have started using RFID to speed up the checkout process and improve customer experience. Some countries have begun using RFID to augment their passports with additional information to verify an individual’s identity. RFID is even used in healthcare, with the FDA certifying the use of RFID to track donated blood, including using RFID tags to track the origin, type, and date of donation for blood [1].</p><p id="">So what’s the catch?&nbsp;Well, with nearly 28 billion RFID tags sold in 2021 and a yearly growth of 36% [2], the sheer volume of these tags will result in significant environmental challenges, due to the wasteful and resource intensive nature of current production methods. In addition, current RFID tags leverage aging material technology that is quickly being supplanted in performance and cost by novel approaches, namely nano copper inks, like <a href="https://www.copprint.com/wp-content/uploads/2021/12/TDS-LF-301-Beta-22-08-21.pdf" target="_blank">Copprint LF-301</a>.</p><h2 id="">Materials used to produce RFID&nbsp;tags</h2><p id="">Nano copper inks offer several advantages over existing materials used in RFID production.&nbsp; The most common way tags are made today is by etching aluminum, a subtractive process similar to how PCBs are made. A laminate of aluminum foil and <a href="https://store.voltera.io/products/pet-5-sheets">PET</a> is put through a chemical process where excess aluminum is subtracted to form the final tag pattern. In contrast, nano copper inks use additive processes where conductor material is deposited onto a substrate in the desired pattern. This results in no copper waste, or toxic chemical byproducts from the production process. What’s more, with an ink like Copprint LF-301 the tag can be made right on a paper substrate such that the RFID tag is compostable, a big change compared to non-recyclable and non-compostable etched aluminum tags.</p><h2 id="">How we printed the RFID&nbsp;tag</h2><p id="">We set out to create an RFID tag using an innovative ink by <a href="https://www.copprint.com/" target="_blank" id="">Copprint</a>. Specifically, we designed, printed, assembled and tested a UHF (ultra-high frequency) RFID tag. This sort of tag is commonly used in asset-tracking applications, like logistics and consumer retail. Using industry-standard design and simulation software, a high-performance UHF RFID tag was designed, but as with everything, you don’t know how something really works until you make your first prototype.</p><h3 id="">Using NOVA</h3><p id="">Fortunately, getting up to speed with a new ink and substrate is a breeze with <a href="https://www.voltera.io/nova" id="">NOVA</a>. Using the Smart Dispenser, combined with the built-in ink calibration workflow, we were able to tune an ink profile to use with Copprint LF-301. What’s more, NOVA’s Vacuum Table module made it a breeze working with paper substrates. After placing the paper on the Vacuum Table, it is held in place until the print is complete. Once the ink was dialed in, and paper substrate was in place, we were ready to print — no upfront costs or time waiting for custom screens to print our prototype pattern: just NOVA, Copprint LF-301, and cardstock paper.</p><p id="">With NOVA set up, we printed the RFID antenna pattern which was based on the Modified Half-Dipole antenna topology which is commonly used in this sort of application. From beginning to end, including surface-mapping with the Smart Probe, it took less than 15 minutes to produce one RFID tag antenna print.&nbsp;&nbsp;</p><p id="">Once printed, we followed the sintering instructions provided by Copprint; sintering is a critical step for nano copper inks as it transforms the structure of the material, from many disconnected microscopic particles of copper to one continuous bulk. This is the magic of Copprint’s ink, as the sintering process transforms the easy-to-print ink into a high performance copper antenna.&nbsp; This is achieved by using a simple oven and heat press, all within our lab.</p><p id="">With the antenna printed and processed, all that was left was to bond the RFID transceiver integrated circuit to the antenna itself. This IC controls the antenna and responds to an incoming RFID signal. While these are often bonded using specialized adhesives known as Anisotropic Conductive Adhesives (ACA), we chose to simply solder the IC to the antenna as the sintered ink behaves just like bulk copper on a PCB. And with that, our tag was complete!</p><h3 id="">Results: How our printed RFID&nbsp;tag performed</h3><p id="">After testing the RFID tag we produced, we were surprised at the performance: this custom tag which was designed and prototyped in-house in a week performed slightly better than the off-the-shelf tag we purchased from a market-volume leader in RFID. This was accomplished with minimal upfront cost, using NOVA to rapidly prototype our design, moreover with the quick production time for each tag, iterations of the design can be rapidly created and tested.</p><h2 id="">Further reading</h2><ul id=""><li>Overview: <a href="https://www.voltera.io/use-cases/applications/printed-antennas" id="">Printed Antennas</a>‍</li><li>White paper: <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper">Printing an RFID Tag with Copper Ink on Paper</a>‍</li></ul><p>Have questions about how NOVA&nbsp;can help with your application? <a href="mailto:sales@voltera.io">Reach out to our Sales team</a>.<br>‍</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-fullwidth" style="padding-bottom:56.206088992974244%" data-rt-type="video" data-rt-align="fullwidth" data-rt-max-width="" data-rt-max-height="56.206088992974244%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/2COFihlYVos?feature=shared"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/2COFihlYVos" title=""></iframe></div></figure><p id="">‍<strong id="">‍</strong><br></p><p id="">[1]<a href="https://www.healthcareitnews.com/news/fda-approves-rfid-based-blood-tracking" target="_blank" id=""> https://www.healthcareitnews.com/news/fda-approves-rfid-based-blood-tracking</a>&nbsp;</p><p id="">[2]<a href="https://rainrfid.org/rain-rfid-market-research-report/" target="_blank" id=""> https://rainrfid.org/rain-rfid-market-research-report/</a>;<a href="https://www.businesswire.com/news/home/20220414005172/en/RAIN-RFID-Tag-IC-2021-Sales-Volume-Rockets-Up-36" target="_blank" id=""> https://www.businesswire.com/news/home/20220414005172/en/RAIN-RFID-Tag-IC-2021-Sales-Volume-Rockets-Up-36</a></p>

Making an RFID Tag using Revolutionary Copper Ink on Paper

We explore the benefits of using nano copper inks to print UHF (ultra high frequency) RFID tags on paper using NOVA. In particular, we printed using Copprint's LF-301 nano copper ink.

We explore the benefits of using nano copper inks to print UHF (Ultra High Frequency) RFID tags on paper using NOVA. In particular, we printed using Copprint's LF-301 nano copper ink.

<h2 id=""><strong id="">Comparing inkjet and extrusion printing methods</strong></h2><p id="">Biomedical electrodes play a crucial role in evaluating the internal processes of the human body by converting biological stimuli into electrical signals. This process is commonly used for <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">electrocardiograms (ECG/EKG)</a>, electromyography (EMG), and electroencephalogram (EEG) procedures, and almost always uses <a href="http://silver/silver chloride (Ag/AgCl)">silver/silver chloride (Ag/AgCl)</a> electrodes with male connector snap closures.&nbsp;</p><p id="">While there are benefits to using these electrodes, they “are susceptible to motion artifacts, can be uncomfortable for the user, and are unsuitable for long term use,” according to <a href="https://www.researchgate.net/publication/361717600_Inkjet_and_Extrusion_Printed_Silver_Biomedical_Tattoo_Electrodes" target="_blank" id="">research</a> by York University’s Yoland El-hajj et al.&nbsp;</p><p id="">In contrast, electrodes printed on tattoo paper offer a promising alternative for monitoring biological activities. In an interview with Voltera, El-hajj noted the best way to acquire signals from the body is to use a sensor that fits seamlessly with the body, rather than a sensor that sits rigidly on the skin.&nbsp;</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/MEW3q7GKYQA"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/MEW3q7GKYQA" title=""></iframe></div></figure><h2 id="">Extrusion printing with NOVA</h2><p id="">In <a href="https://www.researchgate.net/publication/361717600_Inkjet_and_Extrusion_Printed_Silver_Biomedical_Tattoo_Electrodes" target="_blank" id=""><em id="">Inkjet and Extrusion Printed Silver Biomedical Tattoo Electrodes</em></a>, El-hajj et al compared two common methods — <a href="https://www.voltera.io/blog/introduction-inkjet-technology" id="">inkjet printing</a> and extrusion printing — to print the electrodes using silver ink.</p><p id="">According to the study, “Silver-based inks were selected as the printing medium due to their high conductivity, mechanical robustness, biocompatibility, and moderate cost compared to other inks (e.g. gold, graphene).”</p><p id="">Using <a href="https://www.voltera.io/nova" id="">Voltera NOVA</a>, the group studied various shapes to test the performance and signal quality of the printed electrodes. El-hajj noted that, because the tattoo paper is quite thin, it can be used for many functional purposes, such as integration with prosthetic devices.&nbsp;</p><p id="">“This is a starting point. Once the printing parameters for printing the specific ink on the specific substrate are optimized, you can go further. You can work on different sensors that can be integrated with the body, such as strain sensors, or even potentially explore areas of energy harvesting.”&nbsp;</p><p id="">When it came to summarizing how NOVA helped her in this study, El-hajj observed that NOVA makes the printing process more efficient, and calibrating materials and aligning patterns is easier than ever. NOVA is more cost effective and reduces the time it takes to print patterns on a substrate compared to other printing methods, including inkjet.</p><h2 id="">Results: Inkjet vs. extrusion printing</h2><p id="">The research findings indicated that inkjet printed electrodes are ideal for acquiring signals in areas of the body engaged in higher movement (e.g. EMG) due to their ability to better withstand bending strain. However, the extrusion printed electrodes exhibit a lower sheet resistance and impedance, and the ink does not absorb into the paper — a common issue encountered with inkjet printed tattoo electrodes.</p><h3 id="">Inkjet vs. extrusion sheet resistance</h3><ul id=""><li id="">Extrusion printed electrodes: 9.4 mΩ/sq</li><li id="">Inkjet printed electrodes: 25.1 kΩ/sq</li></ul><h3 id="">Inkjet vs. extrusion impedance</h3><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/66bfb968b9af844c0d4bab22_66703583a405e353b91ea7e9_Printed-tattoo-electrodes-inkjet-extrusion-impedance.webp" loading="lazy" alt="A graph showing impedance over contact area" width="auto" height="auto" id=""></div><figcaption id="">Source: <a href="https://ieeexplore.ieee.org/document/9781535" target="_blank" id="">Inkjet and Extrusion Printed Silver Biomedical Tattoo Electrodes</a> published in 2022 IEEE International Conference on Flexible and Printable Sensors and Systems (FLEPS)</figcaption></figure><h2 id="">Conclusion</h2><p id="">Printed silver biomedical tattoo electrodes represent a promising advancement in biomedical monitoring technology. Their potential to offer greater comfort, flexibility, and efficiency, as well as their personalized, non-invasive nature compared to traditional electrode options is paving the way for innovative advancements in healthcare. In fact, El-hajj has gone on to continue her research in biomedical printed electronics, founding her own company called Epictrode Health.&nbsp;</p>

Printed Tattoo Electrodes: Cutting-Edge Biomedical Monitoring

Biomedical electrodes play a crucial role in evaluating the internal processes of the human body by converting biological stimuli into electrical signals. Electrodes printed on tattoo paper offer a promising alternative for monitoring these biological activities

Biomedical electrodes play a crucial role in evaluating the internal processes of the human body by converting biological stimuli into electrical signals. Electrodes printed on tattoo paper offer a promising alternative for monitoring biological activities

<p id="">In our recent webinar, we took a closer look at carbon inks by discussing the advantages of the material, then used it to print a strain gauge sensor with <a href="https://www.voltera.io/nova" id="">NOVA</a>. This article is a comprehensive recap of what we covered.</p><h2 id="">Spotlight on NOVA and NovaCentrix HPR-059 Carbon Black Ink</h2><p id="">During the webinar, we demonstrated printing on NOVA with<a href="https://www.novacentrix.com/product/hpr-059-carbon-black/" target="_blank" id=""> NovaCentrix HPR-059</a>, a water-based carbon conductive ink. Not only is this ink environmentally friendly (clean-up can be done with water instead of harsh chemicals), but it also adheres well on a wide range of substrates like paper, plastics, glass, and metal.</p><h2 id="">The versatility of carbon Inks</h2><p id="">The range of carbon-based inks is vast and can be used in applications such as:</p><ul id=""><li id=""><a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">Direct dispensing</a></li><li id=""><a href="https://www.voltera.io/blog/introduction-screen-printing">Screen printing</a></li><li id="">Flexographic application</li><li id="">Pad printing</li><li id="">Spraying</li><li id="">Dip coating</li><li id=""><a href="https://www.voltera.io/blog/introduction-inkjet-technology">Inkjet printing</a></li></ul><p id="">Resins that can be used for curing are:<br></p><ul id=""><li id="">Water-based</li><li id="">Silicone</li><li id="">Thermoplastic</li><li id="">Polyimide</li><li id="">Thermosetting</li><li id="">Epoxy<br></li></ul><p id="">If you couldn't join us live, we've got you covered! Watch the recording:</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/HulJpAOBWMQ?feature=shared"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/HulJpAOBWMQ" title="Webinar: Printing Electronics with Carbon Ink using NOVA"></iframe></div></figure><h2 id="">Benefits of carbon inks</h2><p id="">Our webinar highlighted a number of key advantages of carbon inks, such as:</p><ul id=""><li id="">Resilience against physical wear like abrasion, scratching, creasing, and flexing.</li><li id="">Chemical inertness, ensuring low reactivity with solvents and other chemicals.</li><li id="">High conductivity and strong adhesion.</li></ul><h2 id="">Applications in printed electronics</h2><h3 id=""><strong id="">EMI/RFI shielding</strong></h3><p id="">Carbon inks have emerged as a highly versatile and valuable material in the electronic industry. One of the key uses of carbon inks is in Electromagnetic Interference (EMI) / Radio Frequency Interference (RFI) shielding, where they are employed to protect electronic devices from electromagnetic and radio frequency interference. This shielding property is crucial in ensuring the proper functioning of sensitive electronic components, preventing any disruption or damage caused by external electromagnetic signals.</p><h3 id=""><strong id="">Printed heaters</strong></h3><p id="">Another significant application of carbon inks is in the production of printed heaters. These heaters are created by printing a carbon ink pattern onto a substrate, which can then generate heat when an electric current is passed through it. This technology finds extensive use in various industries, including automotive, aerospace, and consumer electronics, where it is employed for applications such as defogging windows, heating seats, and warming electronic devices.</p><h3 id=""><strong id="">Medical sensors</strong></h3><p id="">Carbon inks also play a vital role in the development of medical sensors. These printed electronic sensors are designed to monitor various physiological parameters, such as heart rate, blood pressure, and glucose levels, providing valuable data for healthcare professionals. Carbon inks are utilized in the fabrication of these sensors due to their excellent electrical conductivity and biocompatibility, ensuring accurate and reliable measurements while being safe for use in medical applications.</p><h3 id=""><strong id="">Electrostatic dissipation</strong></h3><p id="">Another application for carbon inks is electrostatic dissipation, where the ink is used to control and dissipate static electricity. Static electricity can pose a significant risk in certain environments, particularly in industries such as electronics manufacturing and explosive handling. Carbon inks are incorporated into materials and surfaces to create a conductive path, allowing the safe discharge of static charges and minimizing the potential for damage or accidents.</p><h2 id="">How NOVA’s intuitive UI enables a smooth printing experience</h2><p id="">With the introduction of <a href="https://www.voltera.io/nova" id="">NOVA</a>, Voltera addressed some touch sensing and positioning inefficiencies that were present in the <a href="https://www.voltera.io/v-one" id="">V-One</a>.&nbsp; We recognized the need for a solution that would surpass the current limitations we were encountering and provide an even better user experience.</p><p id="">To achieve this, we implemented strain gauge resistors printed with carbon ink in the design of NOVA. By incorporating strain gauge resistors, we were able to combine the XY and Z axes, accurately measure and interpret touch inputs with utmost precision, and overall ensure a highly responsive and intuitive user interface.</p><p id="">The use of carbon ink in the printing process also added an extra layer of durability to NOVA. Due to carbon ink's exceptional resistance to wear and tear, it was the ideal choice for long-lasting performance. This feature ensures that NOVA can withstand the rigors of daily use, providing users with a reliable and robust touch sensing and positioning solution.</p><h2 id="">What’s next for carbon inks in printed electronics?</h2><p id="">As the domain of printed electronics advances, the significance of carbon inks continues to grow. Their adaptability, efficiency, and durability make them a front-runner for many <a href="https://www.voltera.io/use-cases/applications">applications</a> in the industry. Researchers are still uncovering new properties and uses for carbon black, graphene, and other carbon nanomaterials in printed electronics. For those interested in diving deeper into the subject, stay tuned to our blog for additional resources and research summaries that will offer more in-depth insights.</p><p id="">We'd like to thank everyone who attended the webinar. For those who missed out, or those eager to learn more, don't hesitate to <a href="https://www.voltera.io/contact" id="">reach out.</a></p>

Webinar Recap: Printing Electronics with Carbon Ink

Learn about the advantages of carbon/graphene inks in printed electronics applications like printed sensors, flexible circuits, emi/rfi shielding, and more.

Exploring Applications for Conductive Carbon Inks in Printed Electronics: A Comprehensive Recap on our NOVA Webinar

 Our webinar on carbon inks highlighted NovaCentrix HPR-059's versatility in printed electronics. Covering application methods, benefits, and use in products like NOVA, it explored the inks' potential in shielding, sensors, and more. Access the replay here.

<p id="">In our latest webinar, we dove into the process of printing wearable devices with NOVA on<a href="https://materials.celanese.com/en/products/datasheet/US/Micromax%20Intexar%20TE-11C" id=""> Celanese Intexar™ TE-11C</a> thermoplastic polyurethane (TPU) film using <a href="https://materials.celanese.com/en/products/datasheet/US/Micromax%20Intexar%20PE874" id="">Celanese Intexar™ PE874</a>, a stretchable silver conductive ink.</p><h2 id="">Webinar highlights</h2><h3 id="">Live demonstration of ink calibration</h3><p id="">We kicked off the webinar with a brief overview of <a href="https://www.voltera.io/nova" id="">NOVA</a>, Voltera’s material dispensing system. Our Support Lead, Nathan Shinkar, performed a live demonstration of NOVA’s calibration process, explaining how to fine-tune advanced parameters such as trace width, print height, and nozzle temperature to achieve optimal results.</p><h3 id="">Live demonstration of dispensing inks</h3><p id="">Next, we demonstrated how to dispense materials once the substrate is secured on NOVA’s vacuum table. We discussed methods for securing both flexible and rigid substrates. As with the calibration step, print settings can be adjusted based on your ink and substrate choices within the software. The actual printing of the design took approximately five minutes.</p><h3 id="">Tips and tricks</h3><p id="">As highlighted during the webinar, it’s a good practice to inspect the print results using NOVA’s built-in camera and LED lights. We discussed using selective printing in the software to reprint unsatisfactory features, allowing you to avoid reprinting the entire design.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520fef15ded4d7485ff51e_67520fb671289a854261485c_webinar-recap-printing-wearable-electronics-examination.webp" loading="lazy" alt="Examining print results through NOVA's camera and software" width="auto" height="auto" id=""></div><figcaption id="">Examine print results in NOVA&nbsp;software</figcaption></figure><h2 id="">Conclusion</h2><p id="">As demonstrated in the webinar, the final print exhibited excellent stretchability after being laminated onto a piece of fabric, showcasing NOVA’s ability to work with flexible, stretchable, and conformable substrates, as well as dispense advanced functional materials.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520fef15ded4d7485ff4f9_67520fce1dbf8e6eb501ea3f_webinar-recap-printing-wearable-electronics-fabric.webp" loading="lazy" alt="Hands stretch an electronic design printed on a piece of cloth" width="auto" height="auto" id=""></div><figcaption id="">Printed stretchable circuits laminated onto fabric</figcaption></figure><p id="">A special thanks to everyone who joined and participated in the live chat. Your questions about compatible substrates with NOVA, setting ink temperatures, and prototyping with both V-One and NOVA helped make the webinar interactive and informative.</p><p id="">Didn’t make it to the webinar? Watch it here:</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-center" style="padding-bottom:33.723653395784545%" data-rt-type="video" data-rt-align="center" data-rt-max-width="" data-rt-max-height="33.723653395784545%" data-rt-dimensions="854:480" data-page-url="https://youtu.be/SPKzf2gvkyQ?si=UFeYbc0nIN5MvfSO"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/SPKzf2gvkyQ" title="Webinar: Printing Wearable Electronics with NOVA"></iframe></div></figure><p id="">Interested to learn more? Check out the following resources:</p><ul id=""><li id="">White paper: <a href="https://www.voltera.io/application-whitepapers/printing-ecg-electrodes-biocompatible-gold-ink-tpu" id="">Printing ECG Electrodes with Biocompatible Gold Ink on TPU</a></li><li id="">White paper: <a href="https://www.voltera.io/application-whitepapers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" id="">Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control</a></li><li id="">Video: <a href="https://youtube.com/playlist?list=PLbZdiubRTqoqS9CDbZrtc5kbc-bhfKdUw&si=TpSbDWjqoyVp_tcQ" id="">Previous Voltera webinars on additive electronics</a></li></ul><p id="">We offer <a href="https://www.voltera.io/printing-service" id="">printing as a service</a>, where we can create your prototypes for you. To discuss your PCB printing needs, contact us at sales@voltera.io or <a href="https://meetings.hubspot.com/giovanni-obando/gios-meeting-link?uuid=439b62e5-bb0d-41f6-a392-dcad595889f8" id="">book a meeting</a> with us. To stay informed on upcoming webinars, <a href="https://share.hsforms.com/1BPx4J9lvQ7-8px6MtaXF0w34u2a" id="">subscribe to our newsletter</a>!&nbsp;</p>

Webinar recap: Printing Wearable Electronics

Learn more about our webinar on printing wearable electronics for fitness or biomedical monitoring using NOVA, Voltera’s materials dispensing system.

Webinar recap: Printing Wearable Electronics with NOVA

<h2 id="">CPES 2023 - Montreal</h2><p id="">Voltera will be attending <a href="https://intelliflex.org/cpes2023/" target="_blank" id="">CPES 2023</a> — Canada's Flexible Printable Wearable Electronics Symposium — from May 17-18, 2023 in Montréal. CPES&nbsp;explores the broad spectrum of <a href="https://www.voltera.io/blog/flexible-hybrid-electronics">flexible and hybrid electronics</a> (FHE) including printables and <a href="https://www.voltera.io/use-cases/applications/wearables">wearables</a>, and the value chain required to bring innovative products and applications to market.<br><br>Jesus Zozaya, Voltera CEO and co-founder, will be <a href="https://intelliflex.org/cpes2023/program-agenda/" target="_blank">presenting on May 17</a> at 10:40 a.m.</p><h2 id="">‍<strong id="">Unlocking the future of printed electronics</strong>‍</h2><p id=""><em id="">Electronics are changing. How we make them is changing too. Every day, researchers and product developers are exploring what's possible — pushing the limits of functional materials. Electronics that flex, bend, stretch, and conform are the future. That means the future of electronics is additive. But how can we make printed electronics easier and more accessible for everyone? At Voltera, our mission is to catalyze innovation by removing the barriers to entry. In this presentation, we'll highlight how our customers are using NOVA, our materials dispensing platform, to change electronics as we know it and discover the innovative solutions that will shape our future.</em></p><p id=""><em id="">‍</em>We'll be joining over 65 printed, flexible, and wearable electronics organizations at the event. Be sure to look for the <a href="https://intelliflex.org/cpes2023/exhibitors/" target="_blank">Voltera booth</a> — we'll have <a href="https://www.voltera.io/products/v-one">V-One</a> and <a href="https://www.voltera.io/products/nova">NOVA</a>&nbsp;on display! </p><p id="">Planning to attend?&nbsp;Come by and say hello!</p>

Voltera Attends CPES in Montreal

Voltera will be attending CPES 2023 — Canada's Flexible Printable Wearable Electronics Symposium — from May 17-18, 2023 in Montréal. CPES explores the broad spectrum of flexible and hybrid electronics (FHE) including printables and wearables, and the value chain required to bring innovative products and applications to market.

<h2 id="">The evolution of conductive inks</h2><p id="">Conductive inks have been around for a while and their evolution has been remarkable. From their earliest iterations, which were often made with graphite, to today's advanced silver and copper inks, they have played a critical role in the growth of additive electronics.</p><p id="">In the early days, <a href="https://www.voltera.io/blog/what-is-printed-electronics-conductive-inks" id="">conductive inks</a> were used primarily in low-power applications like <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper">RFID tags</a> and <a href="https://www.voltera.io/use-cases/applications/printed-antennas">printed antennas</a>, but as the technology has improved, their use has expanded to include everything from <a href="https://www.voltera.io/use-cases/applications/electroluminescent-displays">flexible displays</a> to <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">medical sensors</a> to <a href="https://www.voltera.io/use-cases/applications/wearables">wearable electronics</a>.</p><h2 id="">The benefits of our Conductor 3<br></h2><p id="">At Voltera, we've been working with conductive inks for years and we're proud to have played a role in their evolution. Our <a href="https://www.voltera.io/products/v-one">V-One PCB printer</a>, which uses our Conductor 2 ink, has helped countless designers and engineers bring their ideas to life. And now, with the release of <a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml?_pos=1&_fid=b8e0f0127&_ss=c" id="">Conductor 3</a>, we're taking things to the next level.<br></p><p id="">With a host of new improvements over Conductor 2 ink, we're confident that Conductor 3 will be a game-changer for our V-One customers.<br></p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6776f87399ccf14b571741ac_6669b2219256d3f83a152387_Conductor-3-ink-evolution-important-update.webp" loading="lazy" alt="Important update for Conductor 3 inks include faster cure time and no burnishing" width="auto" height="auto" id=""></div><figcaption id="">Conductor 3 overview</figcaption></figure><p id="">First up, let's talk about curing time. With Conductor 2, the curing process could take upwards of an hour, which could be an unwelcome slowdown in the design and prototyping process. With Conductor 3, that time has been cut in half — to 30 minutes — which means you can bring your prototype from an idea to reality even faster.<br></p><p id="">But that's not all! There's no longer a need for burnishing the cured traces or flipping the print upside down for curing. This eliminates the need to fiddle with the clamps, which was a tedious and error-prone step in the V-One workflow when using Conductor 2. If you are working with surface mount components, just dispense the solder paste after curing, print, cure, and dispense solder paste without removing the board.&nbsp;<br></p><p id="">In addition to these time-saving and workflow improvements, Conductor 3 also boasts better performance when hand soldering and re-working. It can be soldered at a lower temperature of just 180°C, making it much easier to work with and is more robust when it comes to re-work, providing greater confidence to make changes or fixes to your prototype. This feature is particularly valuable for those who have had difficulties with finicky fine pitch components.<br></p><h2 id="">Conductor 2 and Flex 2 discontinued</h2><p id="">Effective next week, Conductor 2 and Flex 2 are being discontinued in favor of Conductor 3 which is suitable for use in both <a href="https://www.voltera.io/use-cases/applications">flexible and rigid applications</a>.<br></p><p id="">We're proud of what we've accomplished with Conductor 3, and we can't wait for our customers to try it out for themselves. Whether you're an academic, educator, or engineer, we believe that Conductor 3 will help you take your work to the next level. So go ahead! Give it a try and let us know what you think!<br></p><h4 id=""><a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml?_pos=1&_fid=b8e0f0127&_ss=c" id="">Shop ink</a></h4>

Conductor 3: An Ink Evolution

Conductor 3 is a new ink offered by Voltera that replaces Conductor 2. There are changes to curing, burnishing, and more that might impact your printing processes. 

Conductor 3: An ink evolution

<p id="">We're back in the OPE journal!&nbsp;Click below to read an interview with our co-founder and Product Director, James Pickard. He discusses our new platform, <a href="https://www.voltera.io/nova" id="">NOVA</a>, and highlights some of its <a href="https://www.voltera.io/use-cases/applications">applications for additive electronics</a>. </p><p id="">Read the full interview <a href="https://www.coating-converting.com/epaper/c2com/294/epaper/3460/22/index.html" target="_blank" id="">here</a>.</p>

OPE Journal: Gamechanger in the Additive Electronics Toolkit

We're back in the OPE journal! Click below to read an interview with our co-founder and Product Director, James Pickard. He discusses our new platform, NOVA and highlights some its applications for additive electronics. 

We're back in the OPE journal! Our co-founder and Product Director, James Pickard discusses our new platform, NOVA, and highlights some its applications for additive electronics.

<h2 id=""><strong id="">What is silver/silver chloride ink?</strong></h2><p id=""><strong id="">‍</strong>Silver/silver chloride (Ag/AgCl) is a conductive ink typically used to print electrodes for <a href="https://www.voltera.io/use-cases/applications/bioelectronics">biomedical applications</a>. It’s a non-toxic, environmentally friendly ink with stable electrochemical potential used to create disposable <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">on-skin medical electrodes</a> for biosensors, like "ECG, EEG and TENS electrodes; defibrillator pads; transdermal drug delivery; biomedical sensors and reference electrodes," according to <a href="https://www.creativematerials.com/products/ag-agcl-inks/" target="_blank" id="">Creative Materials</a>.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f46698c7ae46f7043e9_67110db86a6f578ca4a62af9_Materials-feature-silver-silverchloride-ink-biomedical-electronics.webp" loading="lazy" alt="A schematic shows the breakdown of a biomedical electronic that includes Ag/AgCI" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://www.henkel-adhesives.com/nl/nl/industrieen/medische-industrie/medical-electronic-devices.html" target="_blank" id="">Henkel Adhesives</a></figcaption></figure><p id=""><strong id="">Features:</strong></p><ul id=""><li id="">Silver-to-silver chloride ratios can be adjusted and blended to achieve different resistance values and sensitivity levels.&nbsp;</li><li id="">The ink has a smooth surface finish with excellent adhesion and crease resistance when printed onto polyester and plastic substrates.&nbsp;</li><li id="">Silver/silver chloride is compatible with <a href="https://www.voltera.io/blog/introduction-screen-printing">screen printing</a> and <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology">direct-ink-writing</a> printing technology.&nbsp;</li></ul><h2 id=""><strong id="">What applications use silver/silver chloride ink?</strong></h2><h3 id="">Smart health patches</h3><p id=""><strong id="">‍</strong>Used in both healthcare and athletics applications, smart health patches deliver new capabilities in monitoring. These devices can continuously measure heart rate, brain activity, movement, and other body functions. <a href="https://www.quad-ind.com/smart-health-patches-to-run-smart/" target="_blank" id="">Quad Industries’ Smart Health Patch</a>, designed to optimize training for ultra-runners, is made using Henkel’s silver/silver chloride ink.<br></p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f45698c7ae46f7043d1_67110dedfa03888ce2161d5f_Materials-feature-silver-silverchloride-ink-smart-health-patches.webp" loading="lazy" alt="Layer breakdown schematic of a smart health patch" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://www.quad-ind.com/smart-health-patches-to-run-smart/" target="_blank" id="">Quad Industries</a></figcaption></figure><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f46698c7ae46f7043e0_67110e1da3ebac0ff033ef83_Materials-feature-silver-silverchloride-ink-smart-health-patches-chest.webp" loading="lazy" alt="A smart health patch sits directly on the skin" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://www.quad-ind.com/smart-health-patches-to-run-smart/" target="_blank" id="">Quad Industries</a></figcaption></figure><h3 id=""><strong id="">Glucose sensors</strong></h3><p id=""><strong id="">‍</strong>Silver/silver chloride ink is also used to print glucose sensors for continuous glucose monitoring (CGM) patches like Freestyle Libre.</p><p id="">CGM patches are being widely adopted for diabetes management. Rather than pricking a finger several times a day to monitor glucose levels, the CGM continuously measures glucose in the blood and interfaces with a reader device or smartphone app. This allows patients to monitor glucose levels throughout the day and refine the timing for their insulin injections.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67520737710a09f1fb54ade0_67520716e167ea4e9a9fd2ef_Materials-feature-silver-silverchloride-ink-glucose-sensors.webp" loading="lazy" alt="A woman reading a book with a glucose sensor exposed on her arm" width="auto" height="auto" id=""></div><figcaption id="">A woman wearing a gluecose sensor</figcaption></figure><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f46698c7ae46f7043e3_67110e4d4201df8a7c26044c_Materials-feature-silver-silverchloride-ink-glucose-sensors-schematic.webp" loading="lazy" alt="A close up of a glucose sensor with the labels &quot;working electrode&quot;, &quot;reference electrode&quot;, and &quot;counter electrode&quot;" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;Smart Sutures published in <a href="https://www.sciencedirect.com/science/article/abs/pii/B9780128197509000127" target="_blank" id="">Advanced Technologies and Polymer Materials for Surgical Sutures</a></figcaption></figure><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f45698c7ae46f7043d4_67110eadfcd56570faa1993a_Materials-feature-silver-silverchloride-ink-glucose-sensors-device.webp" loading="lazy" alt="An image showing the inside of a glucose sensor" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://www.henkel-adhesives.com/nl/nl/industrieen/medische-industrie/medical-electronic-devices.html" target="_blank" id="">Henkel Adhesives</a></figcaption></figure><p id="">In recent years, CGMs also have become a tool for athletic performance. Endurance athletes use CGMs to monitor for dips in glucose during training, and then methodically dial in their fuel strategy and nutrition plan accordingly. The <a href="https://www.supersapiens.com/" target="_blank" id="">Supersapiens</a> glucose monitoring system is being leveraged by athletes like Crossfit Games champion Samantha Briggs, olympic triathlon gold medalist Kristian Blummenfelt, and endurance obstacle course world champion Ryan Atkins.&nbsp;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/67110f46698c7ae46f7043e6_67110f0d89ff2821638735a8_Materials-feature-silver-silverchloride-ink-athletic-performance.webp" loading="lazy" alt="A woman in a handstand is wearing an electronic patch on her shoulder" width="auto" height="auto" id=""></div><figcaption id="">Image:&nbsp;<a href="https://www.supersapiens.com/" target="_blank" id="">Supersapiens</a></figcaption></figure><p id="">Silver/silver chloride ink can also be paired with <a href="https://store.voltera.io/products/intexar-tpu-5-sheets">TPU</a> used to print stretchable interconnections for constructing <a href="https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6163896/" target="_blank" id="">medical sensor textiles</a> and <a href="https://journals.sagepub.com/doi/abs/10.1177/00405175211005039" target="_blank" id="">smart textile garments</a>. Commercialization has been limited due to lack of cost-effective, standard fabrication processes that can be applied to a large variety of fabrics, but companies like <a href="https://softmatter.io/" target="_blank" id="">Softmatter</a> and <a href="https://www.memtronik.com/printed-electronics/smart-clothing/" target="_blank" id="">Memtronik</a> now offer customized smart-garment design and fabrication.</p><h2 id=""><strong id="">Where can I purchase this ink?</strong></h2><h3 id="">‍<strong id="">Henkel Adhesive Technologies</strong></h3><p id="">If you work in the engineering world, you’re probably familiar with Loctite, a line of products by Henkel Adhesive Technologies. Loctite EDAG 7019 E&amp;C is a silver/silver chloride conductive ink, formulated to provide excellent adhesion to the wide variety of substrates used in the manufacture of electrically conductive medical devices.&nbsp;</p><p id="">Read the datasheet here: <a href="https://tds.henkel.com/tds5/Studio/ShowPDF/?pid=EDAG%207019%20EC&format=MTR&subformat=HYS&language=EN&plant=WERCS&authorization=2" target="_blank" id=""><em id="">LOCTITE EDAG 7019 E&amp;C Technical Data Sheet</em><br><br></a>Henkel also sells a <a href="https://print-your-electronics-with-loctite.com/LOCTITE-SENSOR-DEMONSTRATOR" target="_blank" id="">Loctite sensor demonstrator kit</a> with twelve dry adhesive electrodes for medical research and technical material validation.<br><br>Henkel Adhesive Technologies have developed a wide portfolio of innovative solutions in adhesives, sealants, inks, and functional coatings.&nbsp;</p><h3 id=""><strong id="">Dupont</strong></h3><p id=""><strong id="">‍</strong>Another option is Dupont 5874 silver/silver chloride, which is designed for screen printing on polyester, and is suitable for a wide variety of biomedical applications. Dupont is an industry leader in materials development, combining scientific and applications development expertise to accelerate innovation. <br><br>Read the datasheet here: <a href="https://www.dupont.com/content/dam/dupont/amer/us/en/mobility/public/documents/en/EI-10086-DuPont-5874-Ag_AgCI-Composition-Data-Sheet.pdf" target="_blank" id=""><em id="">Dupont 5874 silver/silver chloride composition for screen printing</em></a></p><h3 id=""><strong id="">Kayaku Advanced Materials</strong>‍</h3><p id="">Kayaku Advanced Materials also offers a silver/silver chloride conductive ink, designed for screen printing medical EEG and EKG sensors. Kayaku develops and manufactures innovative specialty materials to push the latest innovation trends. <br><br>Read the datasheet here: <a href="https://kayakuam.com/wp-content/uploads/2020/03/agcl-675-silver-chloride-ink.pdf" target="_blank" id="">AGCL-675 SILVER/SILVER CHLORIDE INK&nbsp;</a></p><p id=""><strong id="">Still have questions? </strong></p><p id="">Reach out to <a href="mailto:support@voltera.io" id="">support@voltera.io</a>, and one of our specialists will be happy to help point you in the right direction.</p>

Materials Feature: Silver/Silver Chloride Ink

Silver/silver chloride is a conductive ink typically used to print electrodes for biomedical applications. It’s a non-toxic, environmentally friendly ink with stable electrochemical potential used to create disposable on-skin medical electrodes for biosensors, like EKG, EEG, and ECG sensors. It’s also used for medical devices like defibrillator pads, glucose monitors, and drug delivery devices. 

 Materials Feature: Silver/Silver Chloride Ink

Silver/silver chloride is a conductive ink typically used to print electrodes for biomedical applications. It’s a non-toxic, environmentally friendly ink with stable electrochemical potential used to create disposable on-skin medical electrodes for biosensors, like EKG, EEG, and ECG sensors.

<p id="">Is there anything better than a good cup of coffee (or tea!)? It's divine when it's hot, and deliciously refreshing when it's iced.&nbsp;</p><p id="">…But room-temperature coffee? Not so great.&nbsp;</p><p id="">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.</p><p id="">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 <a href="https://www.voltera.io/blog/in-mold-electronics">in-mold electronics</a> (also known as in-mold structural electronics).</p><h2 id="">What are in-mold electronics?</h2><p id="">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;</p><p id="">In IME, the electronics are printed using a standard process of <a href="https://www.voltera.io/blog/introduction-screen-printing">screen-printing</a> 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;</p><h2 id="">What are the applications of in-mold electronics?</h2><p id="">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;</p><p id="">In the image below, all the red components identify the wire in a vehicle:</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf69cd8989ca4a531b2713_6669aa6f363d03946a895756_In-mold-structural-electronics-applications.webp" loading="lazy" alt="A see-thru vehicle shows red lines wherever wires are present in a vehicle" width="auto" height="auto" id=""></div><figcaption id="">Image: <a href="https://www.caranddriver.com/features/g15382171/12-propulsion-technologies-that-will-increase-future-cars-efficiency/?slide=1" target="_blank" id="">Car and Driver</a></figcaption></figure><ul id=""><li id=""><strong id="">One vehicle has 5000 feet of wires = 50 lbs</strong> of copper.</li><li id="">Transporting 50 lbs burns 12 L of gas per year.</li><li id="">70,000,000 new cars produced per year.</li><li id="">840,000,000 L of gas is burned to transport copper cables per year.</li></ul><p id="">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.</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/6752068484bbcc4a5c211f1c_675206633cf6159d9b9caf7b_warming-coffee-in-mold-structural-electronics-automotive-console.webp" loading="lazy" alt="An automotive console with gear box and buttons" width="auto" height="auto" id=""></div><figcaption id="">An IME application in automotives</figcaption></figure><p id=""><a href="https://www.idtechex.com/en/research-article/what-does-2023-hold-for-printed-flexible-electronics/28172" target="_blank" id="">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;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" style="max-width:80%" data-rt-type="image" data-rt-align="center" data-rt-max-width="80%"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf69ce8989ca4a531b275e_6669aacbca0d9360298e5b47_In-mold-structural-electronics-IDTechEx-roadmap-emerging-technologies.webp" loading="lazy" alt="Roadmap for selected emerging printed/flexible electronics technologies" width="auto" height="auto" id=""></div><figcaption id="">Image:<a href="https://www.idtechex.com/en/research-article/what-does-2023-hold-for-printed-flexible-electronics/28172" target="_blank" id=""> IDTechEx</a></figcaption></figure><h2 id="">P<strong id="">rinting a m</strong>ug heater with NOVA</h2><p id="">But let’s get back to Duru’s coffee conundrum.&nbsp;</p><p id="">Using <a href="https://www.voltera.io/nova" id="">NOVA</a>, a <a href="https://mayku.me/formbox" target="_blank" id="">Mayku Formbox</a>, and a <a href="https://formlabs.com/3d-printers/form-2/" target="_blank" id="">Formlabs 3D printer</a>, Duru designed and built a mug heater with in-mold electronics technology.&nbsp;</p><p id="">“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;</p><p id="">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;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf69ce8989ca4a531b2755_6669ab0c68a130d4b131f774_In-mold-structural-electronics-printed-mug-heater-NOVA.webp" loading="lazy" alt="Hands hold the printed traces that make up the design of a mug heater" width="auto" height="auto" id=""></div><figcaption id="">Printed circuit</figcaption></figure><h3 id="">Designing a fully conductive trace without breaks</h3><p id="">“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="">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;</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf69ce8989ca4a531b275b_6669ab49710f8a7e3d68514a_In-mold-structural-electronics-fully-conductive-trace.webp" loading="lazy" alt="The molded circuit" width="auto" height="auto" id=""></div><figcaption id="">The molded circuit</figcaption></figure><h3 id="">Working with NOVA</h3><p id="">Despite the challenges of the project, Duru loved working with <a href="https://www.youtube.com/watch?v=T62cUY8uj8M" target="_blank" id="">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.”</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf69ce8989ca4a531b2758_6669ab894f7b21f78db6ead4_In-mold-structural-electronics-working-with-NOVA.webp" loading="lazy" alt="Wires attach to the mold with traces on it and shows their conductivity" width="auto" height="auto" id=""></div><figcaption id="">Connecting the circuit to power</figcaption></figure><h2 id="">Future applications for in-mold electronics</h2><p id="">In Duru’s eyes, there are so many exciting applications for the technology. “In <a href="https://www.voltera.io/use-cases/applications/bioelectronics">biomedical applications</a>, 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;</p><p id="">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;</p><h2 id="">The experience of an intern at Voltera</h2><p id="">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 biomedical applications — for example the <a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/633c55566e5bffe8db61ba27_NOVA-0082%20-%20Insole%20Case%20Study_v2.pdf" target="_blank">in-sole pressure sensor</a> project I did, or things like <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu">wearable biomarker sensors</a>.”</p><p id="">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;</p>

Warming Your Coffee with In-Mold Structural Electronics

In-mold electronics processes involve printing conductive inks onto moldable plastic films, which are then thermoformed into a desired 3D shape. Learn how this technology has potential to change the form factors of electronic devices all around us. 

Warming Your Coffee with In-Mold Structural Electronics | Flexible Hybrid Electronics

In-mold electronics (IME) processes involve printing conductive inks on moldable plastic films, which are then formed into a desired 3D shape. A Voltera test engineering intern used NOVA and IME manufacturing processes to create an induction mug heater.

<p id="">At the recent TechBlick event in Eindhoven, OPE journal met with the team of Voltera (Kitchener, Canada). Voltera CEO, Jesus Zozaya, highlighted their latest innovation, the <a href="https://www.voltera.io/nova">NOVA</a> platform — discussing exciting possibilities and future developments for organic and printed electronics. </p><p id="">Want to read the full article? <a href="https://www.coating-converting.com/epaper/c2com/291/epaper/9314/20/index.html" target="_blank">Click here and flip to page 21</a>.</p>

Print Anything on Everything — Voltera Makes the Cover of OPE Journal!

At the recent TechBlick event in Eindhoven, OPE journal met with the team of Voltera (Kitchener, Canada).Voltera CEO, Jesus Zozaya, highlighted their latest innovation, the NOVA platform — discussing exciting possibilities and future developments for organic and printed electronics.

Voltera CEO Jesus Zozaya discusses NOVA and the future of printed electronics with OPE Journal at TechBlick

Voltera’s NOVA Smart Probe made the cover of OPE Journal! We were featured in the magazine following an interview by OPE Journal editor, Martin Hirschmann, at TechBlick this year.

<h2>Will it print</h2><p id="">Here at Voltera, we really love the holiday season. We feel like elves in Santa’s workshop, building <a href="https://www.voltera.io/v-one" id="">V-Ones</a> and <a href="https://www.voltera.io/nova" id="">NOVAs</a> to send out to our customers.&nbsp;</p><p id="">We say NOVA can <em id="">print anything on everything</em>. We don’t want to get on Santa’s naughty list for lying, so we’ve put NOVA to the test, printing onto all kinds of things like <a href="https://www.youtube.com/watch?v=UIdVkiWLWTE" target="_blank" id=""><strong id="">curved surfaces</strong></a>, glass, <a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/633c55bfb8ff0328606611fa_NOVA-0057%20-%20Case%20Study%20Wearable%20Tech_woEsther_FINAL.pdf" target="_blank" id=""><strong id="">TPU</strong></a>, cookies…&nbsp;</p><p id="">Wait, what? Cookies?</p><p id="">Yep, you read that correctly. We put a festive twist on NOVA’s capabilities by&nbsp;printing frosting onto a gingerbread cookie.</p><figure id="" class="w-richtext-figure-type-video w-richtext-align-fullwidth" style="padding-bottom:56.206088992974244%" data-rt-type="video" data-rt-align="fullwidth" data-rt-max-width="" data-rt-max-height="56.206088992974244%" data-rt-dimensions="854:480" data-page-url="https://www.youtube.com/watch?v=t5ZXupHwmOU"><div id=""><iframe allowfullscreen="true" frameborder="0" scrolling="no" src="https://www.youtube.com/embed/t5ZXupHwmOU" title="Printing with NOVA: Frosting on a Holiday Cookie"></iframe></div></figure><p id="">“NOVA has the ability to dispense a wide variety of substances (pastes, inks, fluids) onto a wide variety of surfaces. Printed electronics (also known as additive electronics) is a relatively new concept for many electronics engineers and product designers, who may not initially recognize the potential of the machine” said Voltera CEO Jesus Zozaya. “Printing with unconventional materials allows us to explore the question ‘will it print?’ with all kinds of materials that might not be typical for electronics, but are familiar substances or objects that people encounter in their daily lives” he explained.&nbsp;</p><h2>Printing on unconventional materials</h2><p id="">Not everyone knows what <a href="https://www.voltera.io/blog/role-conductive-inks-additive-electronics-manufacturing" id=""><strong id="">conductive ink</strong></a> is, but most of us are familiar with cookie frosting. It’s a way to demonstrate NOVA’s capabilities to a broader audience, and build that intuition of what NOVA can do.&nbsp;</p><p id="">Voltera’s test engineering intern, Daniel Zybine, was responsible for this cookie-cutting-edge research. Daniel’s worked with a lot of unconventional materials, and there are usually some fun troubleshooting challenges involved. Printing on the cookie was no exception and required some creative problem-solving.</p><p id="">“The cookie wasn’t perfectly flat on the bottom, so it would kind of see-saw a little bit” Daniel noted. “When the probe applied pressure on one side of the cookie, it would kind of deflect. We fixed that by putting some frosting under the cookie and gluing it to the parchment paper” he explained. “This project has been edible and tasty, and was very fun. It really helped us get into the holiday spirit.”</p><p id="">This gingerbread cookie experiment also presented an opportunity to highlight specific features of the machine. The frosting design was created using Adobe Illustrator. We’ve been testing out a new feature that allows NOVA to load SVG files, making the software more accessible — especially to anyone with experience using vector-based design tools.&nbsp;</p><p id="">“Historically, we’ve only supported Gerber files”, explained Jesus. “Gerber files are the PDF of the electronics world. Whether you’re designing in Eagle, Altium, or E-Cad, they all end up outputting to Gerber formats. These are the files that you’d normally send out to a factory, usually overseas, to get manufactured into a PCB. The problem is that you need to know how to work with Eagle, Altium, or E-Cad to&nbsp; produce the gerber files, which means you are typically familiar with electronics design”, he said.&nbsp;</p><h2>Making NOVA more accessible</h2><p id="">“We noticed that a lot of our customers — especially those in the education space and even some of the academics — are not necessarily familiar with electronics design”, continued Jesus. They’re familiar with materials or they’re learning electronics design, but something that’s a little bit more intuitive for them are other types of programs like Inkscape or Adobe Illustrator, which work with different file formats,” he said. “SVG has been a highly requested feature for many, many years. I’m really excited about this because it will allow us to make our software a little bit more accessible to people who are not experts at electronics design.”</p><p id="">SVG file support is being beta tested with <a href="https://www.voltera.io/nova" id="">NOVA</a>. Our <a href="https://www.voltera.io/v-one" id="">V-One</a> customers will be thrilled to hear that SVG file support is in development for the V-One, so that’s something to look forward to in the new year.</p><p id="">Happy holidays, and happy printing!</p><p id="">The Voltera Team</p><p id="">P.S. We are just beginning to explore NOVA’s capabilities with our “Will It Print?” experiments. Do you have a suggestion for an unconventional material we should print on or print with? <a href="mailto:hello@voltera.io" id=""><strong id="">Let us know!</strong></a> We’d love to put NOVA to the test!</p>

NOVA - Will It Print Frosting on a Gingerbread Cookie?

Can NOVA really print anything on everything? To get into the holiday spirit, we put NOVA to the test printing frosting onto a gingerbread cookie.

Using NOVA to print frosting on a gingerbread cookie | Will It Print?

We say NOVA can print anything on everything, and we stand by that slogan! To get into the holiday spirit, we put NOVA to the test by using this high-tech additive electronics printer to deposit frosting onto a gingerbread cookie. 

<p id="">If you’re new to the world of additive electronics or <a href="https://www.voltera.io/blog/flexible-hybrid-electronics" target="_blank"><strong id="">flexible hybrid electronics</strong></a>, you probably have a lot of questions when it comes to materials compatibility.&nbsp;</p><p id="">When you’re printing with materials, you typically begin with one of two questions:<br></p><ol id=""><li id="">I have this thing and I want to print on it — <strong id="">what ink can I use?</strong></li><li id="">I have this ink — <strong id="">what can it print on?</strong>‍</li></ol><p id="">For some categories of inks, there are a lot of variables that determine what you can print on — especially if you’re printing onto soft, stretchable, or flexible substrates. <a href="https://store.voltera.io/products/intexar-tpu-5-sheets">Thermoplastic Polyurethane (TPU)</a>, for example, is a stretchable material that can be used to incorporate electronics into textiles — but there are many kinds of TPU and they need to be paired with compatible ink.&nbsp;</p><p id="">When you’re innovating in the field of flexible hybrid electronics, trying to figure out how to <a href="https://www.voltera.io/blog/ultimate-guide-choosing-materials-new-electronics-product"><strong id="">choose materials</strong></a> for your next project can feel a bit like the wild west. If you want to make informed decisions, you need to understand the factors that influence materials compatibility — ink composition, functional compatibility, curing method, and <a href="https://www.voltera.io/blog/what-surface-energy">surface energy</a>.</p><h2 id=""><strong id="">Conductive ink composition</strong></h2><p id="">Conductive inks are typically composed of three main parts:</p><ol id=""><li id=""><strong id="">Filler </strong>— this gives the ink its function — making it conductive, resistive, etc.</li><li id=""><strong id="">Binder </strong>— this gives the ink its structural property after it cures, usually a polymer, to hold the filler particles in place.</li><li id=""><strong id="">Vehicle</strong> — this is a liquid phase that carries everything else to its destination. It can be composed of many different materials like solvents, curing initiators, and other substances that give the ink its particular rheology and flow.</li></ol><p id="">Different kinds of inks have different ratios of filler, binder, and vehicle. These formulations and ratios determine the conductivity of the ink, whether it is rigid, flexible, or stretchable, informs processing conditions and storage conditions, and more. Fortunately, you don’t have to be a materials science expert to figure this stuff out. Datasheets provide details about an ink’s physical properties, composition, processing details, substrate compatibility, etc.</p><p id="">Here are some examples of conductive ink datasheets from <a href="https://www.novacentrix.com/datasheet/Metalon-HPS-FG57B-TDS.pdf" target="_blank" id=""><strong id="">Novacentrix</strong></a>, <a href="https://acimaterials.com/wp-content/uploads/2022/02/ACI-Data-Sheet-SE1109-Rev-1-1.26.22.pdf" target="_blank" id=""><strong id="">ACI Materials</strong></a>, and <a href="https://www.dupont.com/content/dam/dupont/amer/us/en/mobility/public/documents/en/7102.pdf" target="_blank" id=""><strong id="">Dupont</strong></a>.&nbsp;</p><p id=""><a href="https://www.voltera.io/blog/introduction-screen-printing" id=""><strong id="">Screen printable inks</strong></a> can have up to 80% filler by weight — they’re thick, high-viscosity inks. These inks are also compatible with <a href="https://www.voltera.io/products/nova">NOVA</a> and the <a href="https://www.voltera.io/products/v-one">V-One’s</a> <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology"><strong id="">direct ink writing</strong></a> technology.</p><p id=""><a href="https://www.voltera.io/blog/introduction-inkjet-technology" id=""><strong id="">Inkjet inks</strong></a> have less than 20% filler, with a higher proportion of vehicle and binder — they’re watery, low-viscosity inks.</p><h5 id=""><strong id="">Sci-Snack:</strong></h5><p id=""><a href="https://www.voltera.io/blog/what-is-viscosity"><strong id=""><em id="">What is viscosity?</em></strong></a><strong id=""><em id=""> </em></strong><em id="">Viscosity is the measure of a fluid’s resistance to flow, due to the internal friction of the fluid. The viscosity of an ink impacts how it interacts with a substrate and how it interacts with your printing technology, and is a key determining factor when you’re choosing printing technology.</em></p><h2 id=""><strong id="">Conductive inks’ functional compatibility</strong></h2><p id=""><a href="https://www.voltera.io/blog/what-is-printed-electronics-conductive-inks"><strong id="">Conductive ink</strong></a> has two primary jobs — to stay where it’s put and to conduct electricity.&nbsp;</p><p id="">Your ink may have other functions too, like stretching or flexing. If you want your ink to do its jobs properly, there are three general considerations for pairing an ink with a substrate.</p><h3 id="">How to match an ink with a substrate</h3><p id="">If you’re looking for specific functional performance, like flexibility or stretchability, you need to print on a stretchable or flexible substrate using an ink that has flexible or stretchable properties.&nbsp;</p><p id="">Here are some rules of thumb for functionally matching an ink and a substrate:</p><ul id=""><li id="">Rigid ink doesn’t work on flexible or stretchable substrates, because the ink doesn’t have flexible or stretchable properties.&nbsp;</li><li id="">Flexible ink doesn’t work on stretchable substrates, because the ink is formulated to flex, but not formulated to stretch.</li><li id="">Stretchable, flexible, or rigid ink can all be used on a rigid substrate.</li></ul><p id="">[script]https://cdn.prod.website-files.com/6334888a34bfac591c6aa6e9/66e04ca4f46a005a07229180_Blog_Compatibility%20guide%20table%201.txt[/script]</p><p id=""><em id="">*Other properties will impact ink/substrate compatibility, beyond what is depicted in this chart. Read on for more details.</em></p><p id=""><strong id=""><em id="">Note:</em></strong><em id=""> If you’re printing on TPU, you must use an ink that is formulated to match the stretchability of the TPU. If you print onto TPU with an incompatible ink, your traces will crack apart when strain is applied. Also note that TPU can swell due to solvents in certain inks. </em><strong id=""><em id="">When you’re choosing a stretchable conductive ink, ask the ink supplier to recommend a compatible TPU.</em></strong></p><h3 id="">How does curing temperature affect my substrate?</h3><p id="">Some inks just don’t work with some substrates because the temperature required to cure the ink will destroy the substrate.&nbsp;</p><p id="">Most conductive inks are thermally cured. They need to be raised up to a certain temperature in order to evaporate the solvents in the ink and bind the remaining contents together into cured traces. Some substrates can’t withstand high temperatures. <a href="https://store.voltera.io/products/polyimide-5-sheets">Kapton</a> can be heated to 300°C and be perfectly fine, but TPU, <a href="https://store.voltera.io/products/pet-5-sheets">polyethylene terephthalate (PET)</a>, or <a href="https://store.voltera.io/products/3-x-4-substrates">FR4</a> would melt and burn at such a high temperature.&nbsp;</p><h3 id="">How to ensure the ink adheres to the substrate</h3><p id="">Adhesion is a surface property — <a href="https://www.voltera.io/blog/what-surface-energy"><strong id="">the way that two surfaces interac</strong>t</a>. In order for your ink to do its job, it has to adhere to the substrate.&nbsp;</p><p id="">If you print with conductive ink onto super smooth non-stick Teflon, the ink won’t adhere and your cured traces will just pop off the surface. In order to promote adhesion, it’s best if your substrate has micro-scale roughness incorporated into the surface itself, or via a coating. For example, PET can be coated with silica flakes to promote adhesion.</p><h2 id=""><strong id="">Curing methods</strong></h2><p id="">There are two methods to cure ink — thermal heat energy or ultraviolet light energy. Curing converts an ink from its wet, non-functional state to its solid, functional state. The thermal curing process changes the volume of your traces, whereas UV curing does not. It’s important to understand how each process impacts your traces, because ink needs to maintain a particular shape after curing in order to effectively conduct electricity.&nbsp;</p><h3 id=""><strong id="">Thermal curing</strong></h3><p id="">Thermal curing is the most common way of processing an ink. Thermal inks are cured by applying heat to evaporate the solvents in a vehicle, and the remaining binder polymers hold the filler particles in place.&nbsp;</p><p id="">Thermal curing evaporates the solvents in the ink, reducing the volume of the material. You should account for this if you have a specific thickness target after curing.</p><h3 id=""><strong id="">UV&nbsp;curing</strong></h3><p id="">Ultraviolet (UV) inks have a different vehicle makeup than thermal inks. Their uncured phase contains monomers. When exposed to UV light, photoinitiators cause the monomers to bind together, converting them into polymers that hold everything together.&nbsp;</p><p id="">UV-cured inks retain their full volume — nothing evaporates — so the volume of your ink and the shape of your traces remains the same through the curing process.&nbsp;</p><p id="">‍</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://cdn.prod.website-files.com/6334888a34bfac03b46aa715/66bf6aa68e8e15b3f4008302_66699905025b459d26fb0472_Compatibility-guide-inks-substrates-uv-curing.webp" loading="lazy" alt="A pictogram shows a substrate, with an ink coating on top, with Monomer, Oligomer, and Photo-initiator on top of it" width="auto" height="auto" id=""></div><figcaption id="">Source: <a href="https://rimotec.nl/uv-curing/" target="_blank" id="">Rimotec</a></figcaption></figure><h2 id=""><strong id="">Surface energy</strong></h2><p id="">If you’re using high-viscosity screen-printable inks, then surface energy isn’t a particularly important factor. The friction between the molecules in high-viscosity ink negates the forces of surface energy.&nbsp;</p><p id="">If you’re using <a href="https://www.voltera.io/blog/introduction-inkjet-technology">inkjet technology</a>, the surface energy of your ink and the surface energy of your substrate — and how those two energies interact — will dictate if your ink spreads out on the substrate, forms nice contained traces, or beads up like water on a non-stick frying pan. You can <a href="https://www.voltera.io/blog/what-surface-energy"><strong id="">learn more about surface energy here</strong></a><strong id="">.</strong>&nbsp;</p><p id=""><em id="">Surface energy, by definition, is the amount of energy required to increase the surface area of a material. In other words, it’s the energy required to increase the space between the molecules. Each material has its own surface energy based on the chemical composition of the material.</em></p><p id="">If you have specific questions about how to pair an ink with a substrate, reach out and <a href="https://www.voltera.io/book-a-meeting"><strong id="">talk to one of our experts</strong></a>. We love to nerd out on this stuff and want to help you get the answers you need to make your next project a success.&nbsp;&nbsp;</p><p id="">Until next time…</p><p id="">The Voltera Team<br></p><p id="">P.S. Was this blog post helpful? Is there a different topic you’d like to learn more about? <a href="mailto:hello@voltera.io"><strong id="">Let us know!</strong></a> We love answering questions, sharing knowledge, and helping to make the printed electronics industry more accessible to everyone.</p>

A Compatibility Guide for Inks and Substrates

In additive electronics, many variables can impact your work. Learn how factors like ink composition, function, curing method, and surface energy can influence the compatibility of your materials.

A Compatibility Guide for Inks and Substrates | Pairing Materials for Additive Electronics

There are many variables that determine materials compatibility, especially if you’re printing onto soft, stretchable, or flexible substrates. To make informed decisions, you need to understand the factors that influence materials compatibility.

<p id=""><a href="https://www.voltera.io/about/about-us">At Voltera </a>we pride ourselves on transparency and honesty with our customers, so we wanted to let you know about some changes we’ve made to our executive team.</p><p id="">We have recently decided to part ways with our Chief Executive Officer, Alroy Almeida. We cannot stress how difficult this decision was to make, but it was one that was made with Voltera’s future in mind. Our growth, especially in the last few years, has been nothing short of spectacular. It has exceeded our expectations in so many ways and we have Alroy to thank for getting us this far.</p><p id="">Last month <a href="https://www.linkedin.com/in/chuyzoz/" target="_blank">Jesus Zozaya</a> stepped into the role of Chief Executive Officer. Jesus is a co-founder of the company and has held the title of Chief Technology Officer since Voltera’s inception in 2013.</p><p id="">“I am deeply honored to take the reins as Voltera’s CEO,” said Jesus. “Having been with Voltera since the very beginning — when we were just four university students with an idea — it has been an honor to work alongside my friends and watch this company exceed expectations. In the last few weeks alone, it has been exhilarating to see the overwhelmingly positive response to our new product, <a href="https://www.voltera.io/nova" id="">NOVA</a>. I am excited to be at the helm as Voltera continues on this trajectory and I’d like to thank our team for trusting me with Voltera’s next chapter. Most of all I’d like to thank my friend, Alroy, for almost a decade of dedication that has set an incredibly high bar for those of us who follow in his footsteps.”</p><figure id="" class="w-richtext-figure-type-image w-richtext-align-center" data-rt-type="image" data-rt-align="center"><div id=""><img src="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/6668a46ee71e2722fcc9f3cd_Voltera-names-new-CEO-Alroy-Almeida.webp" loading="lazy" alt="" width="auto" height="auto" id=""></div><figcaption id=""><em id="">Former Voltera CEO, Alroy Almeida, holding a customized </em><a href="https://www.voltera.io/v-one" id=""><em id="">V-One</em></a><em id=""> that was gifted to him on his last day at Voltera.</em></figcaption></figure><p id="">As Voltera grows, we hope you’ll stick with us. Our promise to our customers and the additive electronics industry remains unchanged — we will continue to deliver high-quality <a href="https://www.voltera.io/products">products</a> that remove barriers to designing electronics and catalyze innovation in labs and on desks across the world.</p>

Voltera Names New CEO

Voltera makes changes to their execute team, as Jesus Zozaya moves from Chief Technical Officer to Chief Executive Officer

Voltera names a new CEO

Jesus Zozaya, former CTO, steps in as CEO as Voltera continues to grow. 

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