Innovative Processes & Methodologies for Next Generation Sustainable Functional Electronic Components and Systems

Project Information

SusFE

Grant agreement ID: 101070477

DOI

10.3030/101070477

Project closed

EC signature date 25 May 2022

Start date 1 October 2022

End date 31 March 2026

Funded under

• Digital, Industry and Space

Total cost

€ 2 811 561,00

EU contribution

€ 2 811 561,00

Coordinated by

MEDTRONIC IBERICA SA
Spain

Periodic Reporting for period 1 - SusFE (Innovative Processes & Methodologies for Next Generation Sustainable Functional Electronic Components and Systems)

Reporting period: 2022-10-01 to 2024-03-31

Summary of the context and overall objectives of the project

Europe is a frontrunner in digital technologies within sectors like healthcare, automotive, manufacturing, aerospace, defense, and security. However, in emerging fields like post-silicon systems, there is potential for growth. One such area is Functional Electronics, involving the integration of electronic devices through physical principles. It combines Unconventional Nanoelectronics, Flexible, Organic & Printed Electronics, and Electronic Smart Systems. It's applicable in wearables, mobility, health, agriculture, energy, and more. The global market was €15.4 billion in 2017, projected to reach €37.7 billion by 2023. A sustainable approach to eco-design at various levels could enhance its value.

The SusFE project aims to make Functional Electronics environmentally friendly. It focuses on roll-to-roll (R2R) manufacturing, integrating eco-design principles and using sustainable substrates. This will broaden its applications across health, music, sports, agriculture, etc. SusFE will create a toolbox of technology components, including flexible integrated circuits, bioenzymatic fuel cells, and low-power printed sensors. The project will validate these innovations in medical wearables and in vitro diagnostics, like wound monitoring, blood sampling, and diagnostics.

SusFE's goal is to advance eco-friendly R2R manufacturing for versatile applications, enhancing competitiveness in sectors like medical wearables, in vitro diagnostics, and functional electronics, aligning with the EU's broader environmental and economic objectives.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

In WP1, the SusFE project focused on advancing functional electronics and roll-to-roll processing for healthcare applications. Market analysis revealed growing demand for wearable medical devices and green batteries. User and technical requirements were defined for wound monitoring, self-blood sampling, and point-of-care diagnostics, guiding prototype development. The project also refined market analyses for specific medical use cases and ensured regulatory compliance while emphasizing sustainability.

In WP2, the project concentrated on sensor technology for medical applications. They developed pH sensors for wound dressings, ultra-low power sensors for wound monitoring, and point-of-care devices for nucleic acid and protein detection. Achievements included successful integration of pH sensors into flexible foils and significant progress in bioreceptor immobilization techniques.

WP3 focused on advancing analog and digital circuitry on polymer substrates for monitoring systems. They meticulously gathered user requirements, designed intricate circuitry, and developed individual IP blocks essential for wound monitoring and blood sample timestamp systems. The team demonstrated proficiency in developing an IC system able to communicate with a mobile phone when prompted, to transmit reading data.

In WP4, efforts focused on enhancing biofuel cell technology by customizing paper-based bioenzymatic fuel cells for specific applications. T4.1 demonstrated their capability to power primary electronic tasks and explored methods to increase voltage, such as inductively-based voltage boosting circuitry and series connection of fuel cells. T4.2 aimed to raise cell voltage to 4.5V through series connections, showcasing their reliability and relevance for diverse applications in the SusFE project.

WP5 integrated components into Roll-to-Roll (R2R) processes for flexible electronics production. Tasks included assessing substrate compatibility, improving adhesion, integrating sensors, finalizing design for wound monitoring patches, PLA film manufacturing for sensor printing and initiating R2R printing process development for electrochemical sensors. These tasks signify significant progress in ensuring compatibility and reliability of integrated components for healthcare applications.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Silicon Integrated Circuits: Analog and digital circuitry on flexible polymer substrate. FlexIC thickness 30 micrometres, with no noxious materials used for semiconductor, conductors and dielectrics; all in order of mass in nanograms.

PET based multielectrode arrays with nondegradable inks: Additive manufacturing of electrodes with biodegradable materials integrated into biodegradable substrates (cellulose, or textile) will allow significant reduction of permanent waste, and crate soft structures with increased comfort for prolonged use.

Printed alkaline batteries: Bioenzymatic fuel cell that can be recycled and provide mW cm-2 as well providing a more miniaturized solution.

R2R processing: Adhesion processes enhanced by plasma treatment to avoid or reduce solvent and wet chemistry use by a factor>100. Screen printed fluidics, based on the use of nature-derived waxes, is eco-friendlier. Designs for screen printed fluidics will allow cost- and resource-efficient fabrication.

R2R deposition of fragile biological receptor molecule: True R2R processing makes wet chemistry process of antibody / biomolecule deposition obsolete and replaces it with a true in-line R2R processing step for generation of biosensors with immobilisation taking place within 10s of seconds.

Screen printing of the pH-sensor electrodes: Lithographically defined pH-electrodes (line / space 10 – 30 µm) result in more reliable pH-sensing with sensitivity of 0.25pH points.

Optical sensors for pH measurement: Capacitive electrode configurations require fewer components and less energy during operation.

Wound monitoring that allows moisture determination but requires wired contacts to an external reader: Provides multiple physical and chemical parameters including pH with monitoring frequency between 1hr-1 to 4hr-1.

Quantitative blood self-sampling: Self-sampling with a low-cost time stamp with resolution of < 10 mins over 5 days and monitoring of temperature with resolution of 1º Celsius.

SusFE Poster

SusFE Technology Toolbox