1. | EXECUTIVE SUMMARY |
1.1. | Flexible hybrid electronics: Analyst viewpoint (I) |
1.2. | Analyst viewpoint (II) |
1.3. | What is flexible hybrid electronics (FHE)? |
1.4. | Motivating factors for FHE |
1.5. | Comparing benefits of conventional and flexible hybrid electronics |
1.6. | Overcoming the flexibility/functionality compromise |
1.7. | Predicted manufacturing trends for FHE |
1.8. | Supplier opportunities created by FHE adoption |
1.9. | Non-technological barriers to FHE adoption |
1.10. | Where does FHE have a sufficient value proposition? |
1.11. | FHE value proposition for different applications |
1.12. | Technology gaps and potential solutions for FHE to meet application requirements |
1.13. | Materials, components, and manufacturing methods for FHE |
1.14. | Component attachment materials for FHE: Conclusions |
1.15. | Flexible ICs: Conclusions |
1.16. | Flexible batteries for FHE: Conclusions |
1.17. | Energy harvesting for FHE: Conclusions |
1.18. | Flexible substrates for FHE: Conclusions |
1.19. | Conductive inks for FHE: Conclusions |
1.20. | R2R manufacturing for FHE: Conclusions |
1.21. | Use cases for FHE |
1.22. | FHE for electronic skin patches: Conclusions |
1.23. | FHE for e-textiles: Conclusions |
1.24. | FHE for smart packaging: Conclusions |
1.25. | FHE for IoT devices (industrial and domestic): Conclusions |
1.26. | FHE for large area LED lighting: Conclusions |
1.27. | Additive circuit prototyping with FHE: Conclusions |
1.28. | FHE circuit area forecast by application sector |
1.29. | FHE revenue forecast by application sector |
2. | INTRODUCTION |
2.1. | Overview |
2.1.1. | FHE combines the benefits of conventional and purely printed electronics |
2.1.2. | What counts as FHE? |
2.1.3. | Commonality with other established and emerging electronics methodologies |
2.1.4. | Printed electronics is additive, but can be analogue or digital |
2.1.5. | Multilayer PCBs - technically challenging for FHE |
2.1.6. | Overcoming the flexibility/functionality compromise |
2.1.7. | Readiness of FHE for different application sectors |
2.1.8. | FHE value chain: Many materials and technologies |
2.1.9. | Benefits of printing conductive interconnects |
2.1.10. | SWOT analysis: Flexible hybrid electronics (FHE) |
2.1.11. | Ensuring reliability of printed/flexible electronics is crucial |
2.1.12. | Digitization in manufacturing facilitates 'FHE-as-a-service' |
2.1.13. | Alternative routes to FHE manufacturing |
2.1.14. | Standards for FHE |
2.2. | Recent FHE developments |
2.2.1. | VTT improves FHE pilot line capabilities (I) |
2.2.2. | FHE manufacturing of capacitive touch interfaces and flexible lighting. |
2.2.3. | VTT improves FHE pilot line capabilities (II) |
2.2.4. | Emergence of contract manufacturer TracXon for flexible hybrid electronics (FHE) |
2.2.5. | CPI focuses on printed/hybrid electronics for healthcare applications |
2.2.6. | Jabil develops FHE prototypes for healthcare applications |
2.2.7. | Growing interest in utilizing copper ink for FHE (I) |
2.2.8. | Growing interest in utilizing copper ink for FHE (II) |
2.3. | Government funded projects and research centers |
2.3.1. | Government funded projects dominate |
2.3.2. | NextFlex focus on prototype system development |
2.3.3. | Funding of Nextflex project calls |
2.3.4. | Holst Centre develops |
2.3.5. | IMEC collaborates with Pragmatic to develop an 8-bit flexible microprocessor |
2.3.6. | Liten CEA-Tech develops printed batteries and transistors |
2.3.7. | Korea Institute of Machinery and Materials develops R2R transfer method |
2.3.8. | EU Smart2Go project aims to integrate energy harvesting into wearable devices |
2.3.9. | Swedish research center RISE offers hybrid electronics prototyping |
2.3.10. | ITRI develops armband for contactless EMG detection |
2.3.11. | Recent US government funded FHE projects: 2022 |
2.3.12. | Recent US government funded FHE projects: 2021 |
3. | MARKET FORECASTS |
3.1. | Overview |
3.1.1. | Market forecasting methodology: Applications |
3.1.2. | Market forecasting methodology: FHE proportion |
3.1.3. | FHE circuit area forecast by application sector |
3.1.4. | FHE circuit area forecast by application sector (2023, 2028, 2033) |
3.1.5. | FHE revenue forecast by application sector |
3.1.6. | FHE revenue forecast by application sector (2023, 2028, 2033) |
3.1.7. | FHE circuit area forecast for automotive applications |
3.2. | Forecasts by application sector |
3.2.1. | FHE revenue forecast for automotive applications |
3.2.2. | FHE circuit area forecast for consumer applications |
3.2.3. | FHE revenue forecast for consumer applications |
3.2.4. | FHE circuit area forecast for energy applications |
3.2.5. | FHE revenue forecast for energy applications |
3.2.6. | FHE circuit area forecast for healthcare/wellness applications |
3.2.7. | FHE revenue forecast for healthcare/wellness applications |
3.2.8. | FHE circuit area forecast for infrastructure / buildings / industrial applications |
3.2.9. | FHE revenue forecast for infrastructure / buildings / industrial applications |
4. | MATERIALS, COMPONENTS AND MANUFACTURING METHODS |
4.1. | Overview |
4.1.1. | Materials, components, and manufacturing methods for FHE |
4.2. | Component attachment methods and materials |
4.2.1. | Component attachment material: Introduction |
4.2.2. | Differentiating factors amongst component attachment materials |
4.2.3. | Low temperature solder enables thermally fragile substrates |
4.2.4. | Low temperature solder alloys |
4.2.5. | Comparing electrical component attachment materials |
4.2.6. | Photonic soldering gains traction |
4.2.7. | Component attachment materials (for printed/flexible electronics): SWOT analysis |
4.2.8. | Low temperature full metal interconnects with liquid metal solder microcapsules |
4.2.9. | Solder facilitates rapid component assembly via self- alignment |
4.2.10. | Electrically conductive adhesives: Dominant approach for flexible hybrid electronics |
4.2.11. | Example of conductive adhesives on flexible substrates |
4.2.12. | Durable and efficient component attachment is important for FHE circuit development |
4.2.13. | Field-aligned anisotropic conductive adhesive reaches commercialization |
4.2.14. | Conductive paste bumping on flexible substrates |
4.2.15. | Component attachment materials for FHE roadmap |
4.2.16. | Component attachment materials: Readiness level |
4.2.17. | Component attachment materials for FHE: Conclusions |
4.3. | Flexible ICs |
4.3.1. | Flexible ICs: Introduction |
4.3.2. | Fully printed ICs have struggled to compete with silicon |
4.3.3. | Current approaches to printed logic |
4.3.4. | Fully printed ICs for RFID using CNTs emphasize design flexibility |
4.3.5. | Metal oxide semiconductors: An alternative to organic semiconductors |
4.3.6. | Benefits |
4.3.7. | Investment into metal oxide ICs continues |
4.3.8. | Larger flexible ICs can reduce attachment costs |
4.3.9. | Flexible metal oxide ICs target applications beyond RFID such as smart packaging |
4.3.10. | Thinning silicon wafers for flexibility without compromising performance |
4.3.11. | Manufacturing flexible 'silicon on polymer' ICs |
4.3.12. | Embedding thinned silicon ICs in polymer |
4.3.13. | Embedding both thinned ICs and redistribution layer in flexible substrate |
4.3.14. | Silicon thinning process would need to be inserted into existing value chain |
4.3.15. | Where will bespoke or natively flexible processes be required? |
4.3.16. | Comparing flexible integrated circuit technologies |
4.3.17. | Flexible ICs: SWOT analysis |
4.3.18. | Roadmap for flexible ICs technology adoption |
4.3.19. | Flexible ICs: Conclusions |
4.4. | Printed and mounted sensors |
4.4.1. | Printable sensing materials: Introduction |
4.4.2. | What defines a printed sensor? |
4.4.3. | Overview of specific printed/flexible sensor types |
4.4.4. | Drivers for printed/flexible sensors |
4.4.5. | FHE enables IoT monitoring and 'ambient computing' |
4.4.6. | Screen printing dominates printed sensor manufacturing |
4.4.7. | Polymeric piezoelectric materials receive increasing interest |
4.4.8. | Sensing for industrial IoT |
4.4.9. | Sensing for wearables/AR |
4.4.10. | Companies looking to incorporate printed/ flexible sensors often require a complete solution |
4.4.11. | Printable temperature sensors |
4.4.12. | MEMS for flexible hybrid electronics |
4.4.13. | Printable sensor materials: SWOT analysis |
4.4.14. | Printed sensor materials: Readiness level assessment |
4.4.15. | Printed sensors for FHE: Conclusions |
4.5. | Thin film batteries |
4.5.1. | Thin film batteries and power sources |
4.5.2. | 'Thin', 'flexible' and 'printed' are separate properties |
4.5.3. | Major battery company targets printed/flexible batteries for smart packaging |
4.5.4. | Printed flexible batteries in development for smart packaging |
4.5.5. | Printed and coin cell battery integration for FHE smart tags |
4.5.6. | Using a thin film battery as an FHE substrate |
4.5.7. | FHE as a power conditioning circuit |
4.5.8. | Technology benchmarking for printed/flexible batteries |
4.5.9. | Flexible batteries: SWOT analysis |
4.5.10. | Application roadmap for printed/flexible batteries |
4.5.11. | Flexible batteries for FHE: Conclusions |
4.6. | Energy harvesting for FHE |
4.6.1. | Energy harvesting for FHE: Introduction |
4.6.2. | Epishine is leading the way in solar powered IoT, but no attempt to integrate with FHE yet |
4.6.3. | Perovskite PV could be cost-effective alternative for wireless energy harvesting |
4.6.4. | Saule Technologies: Perovskite PV developer for indoor electronics |
4.6.5. | Energy harvesting from EM spectrum |
4.6.6. | Thermoelectrics as a power source for wearables |
4.6.7. | Flexible PV for energy harvesting: Readiness level assessment |
4.6.8. | Flexible PV for energy harvesting: SWOT analysis |
4.6.9. | Power sources for FHE roadmap by application sectors |
4.6.10. | Energy harvesting for FHE: Conclusions |
4.7. | Flexible substrates |
4.7.1. | Substrates for printed/flexible electronics: Introduction |
4.7.2. | Cost and maximum temperature are correlated |
4.7.3. | Properties of typical flexible substrates |
4.7.4. | Comparing stretchable substrates |
4.7.5. | Thermoset stretchable substrate used in multiple development projects |
4.7.6. | External debris and protection/cleaning strategies |
4.7.7. | Paper substrates: Advantages and disadvantages |
4.7.8. | Specialist paper substrates can have properties comparable to polymers |
4.7.9. | Sustainable RFID tags with antennae printed on paper |
4.7.10. | Dimensional stability: Importance and effect of environment |
4.7.11. | Manipulating polyester film microstructure for improved properties |
4.7.12. | Heat stabilization of polyester films |
4.7.13. | Roadmap for flexible substrate adoption |
4.7.14. | Flexible substrates for FHE: Conclusions |
4.8. | Conductive inks |
4.8.1. | Conductive inks: Introduction |
4.8.2. | Challenges of comparing conductive inks |
4.8.3. | Segmentation of conductive ink technologies |
4.8.4. | Conductive ink companies segmented by conductive material |
4.8.5. | Market evolution and new opportunities |
4.8.6. | Balancing differentiation and ease of adoption |
4.8.7. | Interest in novel conductive inks continues |
4.8.8. | Copper inks gaining traction but not yet widely deployed |
4.8.9. | Companies continue to develop and market stretchable/thermoformable materials |
4.8.10. | Higher nanoparticle ink prices offset by conductivity |
4.8.11. | Conductive inks: SWOT analysis |
4.8.12. | Conductive inks: Readiness level assessment |
4.8.13. | Conductive inks for FHE: Conclusions |
4.9. | Printing methods and R2R manufacturing |
4.9.1. | R2R manufacturing: Introduction |
4.9.2. | Can R2R manufacturing be used for high mix low volume (HMLV)? |
4.9.3. | What is the main commercial challenge for roll-to-roll manufacturing? |
4.9.4. | Examples of R2R pilot/production lines for electronics |
4.9.5. | Commercial printed pressure sensors production via R2R electronics |
4.9.6. | Emergence of a contract manufacturer for flexible hybrid electronics (FHE) |
4.9.7. | Applying 'Industry 4.0' to printed electronics with in-line monitoring |
4.9.8. | Applications of R2R electronics manufacturing |
4.9.9. | Comparison of printing methods: Resolution vs throughput |
4.9.10. | R2R manufacturing: SWOT analysis |
4.9.11. | R2R manufacturing: Readiness level |
4.9.12. | R2R manufacturing for FHE: Conclusions |
5. | USE CASES FOR FHE |
5.1. | Overview |
5.1.1. | Use cases for FHE |
5.1.2. | Technology gaps and potential solutions to meet application requirements |
5.2. | Electronic skin patches |
5.2.1. | Benefits of electronic skin patches as a form factor |
5.2.2. | Development from conventional boxed to flexible hybrid electronics to fully stretchable |
5.2.3. | Electronic skin patches within wearable technology progress |
5.2.4. | Skin patch applications overview |
5.2.5. | Interest in skin patches for continuous biometric monitoring continues |
5.2.6. | Material requirements for an electronic skin patch |
5.2.7. | Material suppliers collaboration has enabled large scale trials of wearable skin patches |
5.2.8. | Progress in using liquid metal alloys as stretchable inks for wearable electronics |
5.2.9. | Growing interest in liquid metal wiring for stretchable electronics (II) |
5.2.10. | 'Full-stack' material portfolios reduce adoption barriers |
5.2.11. | R2R pilot line production of skin patch with FHE. |
5.2.12. | Printed batteries in skin patches |
5.2.13. | Electronic skin patch manufacturing value chain |
5.2.14. | Electronic skin patch manufacturing process |
5.2.15. | Offering S2S and R2R production enables different order sizes |
5.2.16. | Increased demand for wearable/medical manufacturing leads to expansion plans |
5.2.17. | Utilizing existing screen-printing capabilities for electronic skin patches |
5.2.18. | GE Research: Manufacturing of disposable wearable vital signs monitoring devices |
5.2.19. | NextFlex: Utilizing electronics in silicone to make more comfortable skin patches |
5.2.20. | Key points: Materials for electronic skin patches |
5.2.21. | FHE for electronic skin patches: SWOT analysis |
5.2.22. | FHE for electronic skin patches: Conclusions |
5.3. | E-textiles |
5.3.1. | E-textiles can utilize FHE for component integration |
5.3.2. | E-textiles represent a small market share for biometric monitoring |
5.3.3. | Industry challenges for e-textiles |
5.3.4. | Three competing approaches to e-textile manufacturing |
5.3.5. | Conductive ink requirements for e-textiles |
5.3.6. | Permeability of particle-free inks enable direct metallization of fabric to form e-textiles |
5.3.7. | Embedding electronics in a box avoids washability issues |
5.3.8. | Patterning and design may be used to supplement capabilities of printed conductive inks |
5.3.9. | Comparing conductive inks in e-textiles |
5.3.10. | Challenges with conductive inks in e-textiles |
5.3.11. | Sensors used in smart clothing for biometrics |
5.3.12. | Electronic components are joined by connectors |
5.3.13. | Connector designs and implementations |
5.3.14. | Overview of components in e-textiles |
5.3.15. | Commercial progress with e-textile projects |
5.3.16. | FHE for e-textiles: SWOT analysis |
5.3.17. | FHE for e-textiles: Conclusions |
5.4. | Smart packaging |
5.4.1. | Smart packaging: An ideal candidate for FHE |
5.4.2. | Motivation for smart packaging: Logistics and safety |
5.4.3. | Motivation for smart packaging: Improving sales and consumer engagement |
5.4.4. | Current status of smart packaging market |
5.4.5. | RFID tags with printed silver antennas on paper substrates |
5.4.6. | Copper ink for RFID antennas offers reduced costs and improved sustainability? |
5.4.7. | FHE with printed batteries and antennas for smart packaging |
5.4.8. | Simpler FHE circuits achieve easier market traction |
5.4.9. | Established semiconductor manufacturer explores FHE circuits for smart packaging |
5.4.10. | Smart packaging requirements can be fulfilled with simpler, cheaper ICs. |
5.4.11. | FHE controls OLEDs for smart packaging |
5.4.12. | Smart-packaging to improve pharmaceutical compliance |
5.4.13. | Smart tags with a flexible silicon IC |
5.4.14. | 'Sensor-less' sensing of temperature and movement with |
5.4.15. | FHE for smart packaging: SWOT analysis |
5.4.16. | FHE for smart packaging: Conclusions |
5.5. | IoT devices (industrial and domestic) |
5.5.1. | IoT devices (industrial and domestic): An emerging opportunity for FHE, |
5.5.2. | Industrial asset tracking/monitoring with FHE |
5.5.3. | Integrating a flexible IC within a multimodal sensor array |
5.5.4. | Capacitive sensors integrated into floors and wall panels |
5.5.5. | Integrated electronics enable industrial monitoring |
5.5.6. | Multi-sensor wireless asset tracking system demonstrates FHE potential. |
5.5.7. | Passive UHF RFID sensors for structural health monitoring |
5.5.8. | FHE for IoT devices: SWOT analysis (I) |
5.5.9. | FHE for IoT devices (industrial and domestic): Conclusions |
5.6. | Lighting |
5.6.1. | FHE for large area lighting: Introduction |
5.6.2. | FHE contract manufacturer produces large area LED lighting |
5.6.3. | R2R etching competes with FHE |
5.6.4. | R2R manufactured LED lighting on foil |
5.6.5. | Directly printed LED lighting (I) |
5.6.6. | Directly printed LED lighting (II) |
5.6.7. | FHE for large area lighting: SWOT analysis |
5.6.8. | FHE for large area LED lighting: Conclusions |
5.7. | Prototyping |
5.7.1. | Additive circuit prototyping with FHE: An introduction |
5.7.2. | Additive circuit prototyping landscape |
5.7.3. | Prototyping flexible 2D circuits with additive electronics |
5.7.4. | Multilayer circuit prototyping |
5.7.5. | Affordable pick-and-place for prototyping and small volume manufacturing |
5.7.6. | Readiness level of additive circuit prototyping |
5.7.7. | Additive circuit prototyping with FHE: Conclusions |
6. | COMPANY PROFILES |
6.1. | American Semiconductor |
6.2. | ACI Materials |
6.3. | Alpha Assembly |
6.4. | BeFC |
6.5. | Boeing |
6.6. | Coatema |
6.7. | Copprint |
6.8. | CPI |
6.9. | DoMicro |
6.10. | DuPont |
6.11. | Elantas |
6.12. | Electroninks |
6.13. | GE Healthcare |
6.14. | Henkel |
6.15. | Heraeus |
6.16. | Holst Center |
6.17. | Indium |
6.18. | InnovationLab |
6.19. | Inuru |
6.20. | IOTech |
6.21. | Jabil |
6.22. | Laiier |
6.23. | Liquid Wire |
6.24. | Molex |
6.25. | Muhlbauer |
6.26. | Nano Dimension |
6.27. | NextFlex |
6.28. | Optomec |
6.29. | Panasonic Electronic Materials |
6.30. | PragmatIC |
6.31. | PrintCB |
6.32. | PVNanoCell |
6.33. | Safi-Tech |
6.34. | Saralon |
6.35. | Screentec |
6.36. | Sun Chemical |
6.37. | Sunray Scientific |
6.38. | TraXon |
6.39. | VTT |
6.40. | Wiliot |
6.41. | Ynvisible |
6.42. | Ynvisible/Evonik/EpishineContact IDTechEx |