Conductive Inks. Innovations For New Applications

Conductive Inks:
Innovations for New Applications

Section title
Dr Matthew Dyson - Principal Technology Analyst, IDTechEx

www.IDTechEx.com
Originally Broadcast January 2023
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Agenda
1. Introduction
2. Challenges for conductive inks
3. Ink requirements for emerging applications
4. Commercialization examples
5. Roadmap and summary www.IDTechEx.com/ink

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Section title
Introduction
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Conductive Inks: What and Why?
What are they? Why are they needed?
− Printable conductive materials. − Enable additive manufacturing, reducing

material waste.
− Typically comprise conductive (usually
metal) particles, polymeric binders, solvent. − Enable digital manufacturing, facilitating rapid
prototyping and ‘mass customization’.
− Usually require curing to increase
conductivity. − Printability enables high-throughput roll-to-roll
manufacturing.
− Conductivity is less than bulk metals.
− Properties (such as stretchability) can be
tailored to application requirements.
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Segmenting Conductive Inks
Conductive
inks
Conductive
Metals Carbon
polymers
Conductive inks
Silver Carbon black

Particle-free Macromolecular
Flakes Nanoparticles Nanowires
(molecular) (CNT, graphene)
Carbon
Copper nanotubes
(CNTs) Segmentation by formulation
Other Graphene
Segmentation by conductive material
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Comparing Conductivities
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Particle-Free Inks: In-Situ Metallization
Particle-free
ink
Nanoparticle-
based ink
A mirror produced on the

inside of a test-tube by
reduction of a silver salt.
Source: Wikipedia
SEM images of sintered particle-free ink (top) and nanoparticle-based ink (bottom).
Source: Electroninks at AME Academy Feb 2021
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Copper Inks: Avoiding Oxidation
Prototype FHE circuit, formerly made from silver ink and now with copper ink.
This mimics an end-user application for healthcare devices, incorporating
heating and wireless capabilities along with sensing.
Source: IDTechEx photos at LOPEC 2022.
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Comparing Properties of Selected Copper Inks
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Challenges for
Section title
Conductive Inks
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Challenges of Comparing Conductive Inks
Surface Robustness
roughness of printed
traces
Compatibility
Longevity / with desired Conductivity
shelf-life printing (AC) -
method including RF
Durability to
Conductivity moisture /
(DC) thermal
cycling
Minimum Compatibility
Curing time / with solder/
temperature radius of
curvature conductive
adhesives
Maximum
Rheology/ extension
viscosity ratio /
stretchability
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Balancing Differentiation and Ease of Adoption
Widely available attributes with Offers distinct benefits with

generic (and/or interchangeable) generic (and/or interchangeable)
processing parameters. processing parameters.
Ease of adoption by customers

E.g., an established flake-based ink E.g., a more conductive ink that is
with adequate conductivity but is compatible with existing
easy to screen print / sinter with printing/sintering methods.
existing equipment.
Similar performance Requires specific desirable

characteristics but specific processing parameters.
processing requirements.
E.g., an ink with a lower
temperature sintering. This will still
require investment and introduce
supply chain risk.
Degree of differentiation
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Reducing Adoption Barriers by Supplying Printer and Ink
ChemCubed offers optimized PVNanoCell offers ink and process

printers and training optimization assistance
Source: ChemCubed Source: PVNanoCell at 3D Electronics Conference

2021
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Reducing the Cost of Using Conductive Ink
How can ink design help customers
Increase conductivity – reduced the amount of ink required

reduce costs?
Maximize printing yield – make ink long lasting, tolerant of

processing variation
Ink formulation – use solvents that are easy to dispose of,

reduce processing temperatures
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Ink Requirements for
Section title
Emerging Applications
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Conductive Ink Application Requirements
Stretchable Digital-
Highly
Low cost Durable /Thermoform printing
Conductive
able compatible
manufacturing
Flexible hybrid electronics 4 4 2 4 4
Circuit In-mold electronics (IME) 2 4 4 3 2
3D electronics 2 4 2 3 5
Circuits for E-textiles 3 4 5 2 1
Circuit prototyping 2 2 1 3 5
Capacitive touch sensors 3 3 1 3 1
Sensing
Pressure sensors 3 3 2 2 1
Biosensors 3 2 2 2 1
Strain sensors 2 3 2 2 1
Electrodes 4 4 4 2 2
Charge extraction from photovoltaics 3 5 0 4 1
applications
Heaters 4 4 1 1 1
Other
EMI shielding 3 3 1 4 5
Antennas (for communications) 3 3 1 5 3
RFID and smart packaging 5 1 0 3 2
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Conductive Ink Requirements for In-Mold Electronics
• Adhesion: Withstand humidity/temperature

stress conditions – automotive qualification
requirements are stringent.
• Curing and drying: Temperatures should be kept

around 120C or below so as not to adversely
affect the plastic.
• Withstand thermoforming and injection

molding: Greater integration requires high yields.
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Conductive Ink Requirements for E-textiles
Conductive inks for e-textiles must satisfy the following requirements:
1. Stretchability: Many e-textile applications don’t need the 50% or 100%

strain that is sometimes demonstrated, 20% is adequate for many
applications. 5000 repetitions is widely used.
2. Washability: The most common comparison metric is the decline in

conductivity over 50 washes – this is typically at a low temperature (40 C)
delicates cycle.
3. Compatibility with stretchable substrate (textile or polymer) and

encapsulant: Adhesion in the harsh environment of washing and repeated
stretching is clearly important – offering a material portfolio (including the
substrate and encapsulant) is a common approach.
4. Well-defined interaction with textile: Does the ink sit on top the textile or
permeate? Ink manufacturers should specific textile types, or offer
recommendations for tested materials Source: Myant at InnoLAE 2021
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Further Application Analysis in the Report
Conductive ink
applications
Circuit
Sensing Other applications
manufacturing
Flexible hybrid Capacitive touch Charge extraction

electronics sensors from photovoltaics
In-mold
Pressure sensors Heaters
electronics
3D electronics Biosensors EMI shielding
Circuits for e- Antennas (for

www.IDTechEx.com/ink
Strain sensors
textiles communications)
Sample pages are available for this report
RFID and smart

Circuit prototyping Electrodes
packaging
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Section title
Commercialization Examples
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RFID Tags With Printed Antennas
− Conventional RFID tags (~99%) have stamped or etched

or antennas.
− Increasing interest in making antennas from copper ink –

it offers lower costs and sustainability benefits.
− Paper can be used as a substrate, further improving

sustainability.
Source: Printed copper RFID tags at LOPEC

2022. IDTechEx photo from Copprint.
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Printed Silver Inks for Transparent Capacitive Touch
Transparent sensor films with a printed metal mesh are already HMI parts utilizing PolyIC’s transparent touch technology. Image source:
deployed in commercially available vehicles. IDTechEx photo at Electronica 2022.
Source: PolyIC at LOPEC 2022
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Leak Sensing With Printed Carbon Inks
• Leak sensors are made

from low-cost carbon ink
printed onto PET.
• Generally resistive, can be

capacitive.
• Have been commercialized

via a building insurance
company.
• Working with contract

manufacturer OKdo.
Source: IDTechEx photo at Electronica 2022 - Laiier
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Stretchable Inks for Printed Heaters
• Integrated heaters are the most

successful e-textile functionality – unlike
biometric monitoring there’s no
competition with smart watches.
• Stretchable conductive inks promise a

more comfortable garment than
embedded wiring, and potentially lower
production costs.
• Heated outer coats utilizing stretchable

conductive ink are currently in the
development stages.
Source: ACI Materials
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Section title
Roadmap and Summary
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Readiness Level of Conductive Inks
Concept Commercialization
Semi-commercial Advanced
Proof of concept R&D Market Launch Market Growth Market Maturity
prototyping prototyping
Flake-based silver inks
Nanoparticle-based silver
inks
Particle-free ink
Copper ink
Stretchable/thermoformable ink
Metal gel based ink (also stretchable)
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Readiness Level of Conductive Ink Applications
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Forecast: Overall Conductive Ink Volume
(Segmented by Ink Type)
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Summary
• Growth in printed electronics to drive growth in conductive inks – will

enable ubiquitous and integrated electronics.
• Extensive opportunities for differentiation, given the wide range of

applications. This includes stretchable/thermoformable inks for wearable
technology/in-mold electronics, and particle-free inks for conformal EMI
shielding.
• Reducing adoption barriers, such as time-consuming process optimization

for each printer, is key to accelerating adoption.
www.IDTechEx.com/ink
Contact Us: Sample pages are available for this report
research@IDTechEx.com Europe: +44 1223 812 300

www.IDTechEx.com Americas: +1 617 577 7890
Asia (Japan): +81 3 3216 7209
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QSection
& A title
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Q&A
− How are stretchable conductive inks developing in the market?
− Copper ink has been discussed as a substitute for silver for years – what’s different this time?
− Smart packaging is a large addressable market for conductive ink – are we any closer to
seeing significant adoption.
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Contact us to explore how we can
support your business.
Research: research@IDTechEx.com
Section title
m.dyson@IDTechEx.com
Europe (UK) Rest of World

Cambridge: +44 1223 812300 Asia (Japan): +81 3 3216 7209
USA
Boston: +1 617 577 7890
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Conductive Inks. Innovations For New Applications

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Conductive Inks:

Innovations for New Applications

Dr Matthew Dyson - Principal Technology Analyst, IDTechEx

Originally Broadcast January 2023

Printed & Flexible

2. Challenges for conductive inks

3. Ink requirements for emerging applications

5. Roadmap and summary www.IDTechEx.com/ink

Printed & Flexible

• Technology assessment • Company profiling • Market forecasts

Reports | Subscriptions | Consulting | Journals | Webinars

Printed & Flexible

Supporting you at each crucial decision making step

Market Commercialization Product Ongoing

Printed & Flexible

IDTechEx data at your command:

www.IDTechEx.com/Subscriptions Our extensive knowledgebase & analysts

Printed & Flexible

Printed & Flexible

What are they? Why are they needed?

− Printable conductive materials. − Enable additive manufacturing, reducing

Printed & Flexible

Silver Carbon black

Segmentation by conductive material

Printed & Flexible

Printed & Flexible

A mirror produced on the

Printed & Flexible

Source: IDTechEx photos at LOPEC 2022.

Printed & Flexible

Printed & Flexible

Printed & Flexible

Printed & Flexible

Widely available attributes with Offers distinct benefits with

Ease of adoption by customers

Similar performance Requires specific desirable

Printed & Flexible

ChemCubed offers optimized PVNanoCell offers ink and process

Source: ChemCubed Source: PVNanoCell at 3D Electronics Conference

Printed & Flexible

How can ink design help customers

Increase conductivity – reduced the amount of ink required

Maximize printing yield – make ink long lasting, tolerant of

Ink formulation – use solvents that are easy to dispose of,

Printed & Flexible

Printed & Flexible

Printed & Flexible

• Adhesion: Withstand humidity/temperature

• Curing and drying: Temperatures should be kept

• Withstand thermoforming and injection

Printed & Flexible

Conductive inks for e-textiles must satisfy the following requirements:

1. Stretchability: Many e-textile applications don’t need the 50% or 100%

2. Washability: The most common comparison metric is the decline in

3. Compatibility with stretchable substrate (textile or polymer) and

Printed & Flexible

Flexible hybrid Capacitive touch Charge extraction

3D electronics Biosensors EMI shielding

Circuits for e- Antennas (for

RFID and smart

Printed & Flexible

Printed & Flexible

− Conventional RFID tags (~99%) have stamped or etched