Sustainable materials and process for green printed electronics (Sustain-a-Print) (SaP)

Project Information

Sustain-a-Print

Grant agreement ID: 101070556

DOI

10.3030/101070556

Project closed

EC signature date 22 June 2022

Start date 1 October 2022

End date 30 September 2025

Funded under

• Digital, Industry and Space

Total cost

€ 4 135 317,50

EU contribution

€ 4 135 317,50

Coordinated by

TEKNOLOGISK INSTITUT
Denmark

Periodic Reporting for period 1 - Sustain-a-Print (Sustainable materials and process for green printed electronics (Sustain-a-Print) (SaP))

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

Summary of the context and overall objectives of the project

The Sustain-a-Print (SaP) project, funded under Horizon Europe, addresses the urgent need for sustainable solutions in electronics. Aligning with the EU’s Circular Economy Action Plan, SaP aims to reduce the environmental impact of electronics manufacturing and waste through innovative printed electronics (PE). The project responds to the rapid growth of electronic waste, increasing by 2% annually, with less than 40% currently recycled within the EU. Resource scarcity and environmental degradation necessitate new designs prioritizing reuse, repair, and high-quality recycling.
SaP’s goal is to embed sustainability into each stage of the PE lifecycle, including material selection, processing, assembly, and end-of-life (EoL) management. The project targets the replacement of fossil-based materials with recycled, bio-based, and biodegradable alternatives, supporting the EU's Bioeconomy Action Plan.
Main Objectives and Ambition
SaP is structured around four main objectives:
1. Reuse and Recycling of PE Materials: Develop methods for reusing and recycling valuable PE materials, ensuring they meet industrial end-user (IEU) specifications, including isolating nanomaterials (NMs) and producing high-purity recycled metal-based precursors.
2. Sustainable Material Development: Create new sustainable materials and formulations for PE, using bio-based or recycled sources, including lignin-based conductive NMs and PLA-based substrates with enhanced properties.
3. Formulation Development: Innovate sustainable formulations for PE printing, including developing conductive inks from recycled NMs and adhesives with de-bond-on-demand properties.
4. Sustainable PE Production: Implement sustainable digital printing and assembly processes for PE, aiming to reduce material usage and curing times while ensuring product durability in harsh environments.
Pathway to Impact
SaP aims to bring sustainable PE methods and materials closer to market through demonstration models, contributing to the circular economy and sustainability in the electronics sector. Key innovations include:
• Recycling and Resynthesis: Develop scalable methods to recycle and reuse over 90% of metals used in PE, reducing reliance on mined materials.
• Biodegradable and Recyclable Materials: Create fully biodegradable and recyclable PE products, validated through industrial end-user cases like membrane switches and electrochemical biosensors.
• Advanced Digital Printing: Demonstrate digital printing technologies that reduce material usage by 30% and curing times by 20%, enhancing production efficiency and cost-effectiveness.
Societal and Environmental Impact
SaP’s innovations are expected to significantly reduce CO2 emissions associated with PE production by using recycled and biodegradable materials. The project’s holistic approach to sustainability will benefit the environment and provide economic advantages by reducing production costs and dependency on imported raw materials. The adoption of SaP’s solutions by the EU electronics industry will reinforce European leadership in sustainable electronics and contribute to climate neutrality.

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

The SaP project has made significant progress in its first 18 months, focusing on advancements in PE. Key achievements include:
1. Sustainable Materials:
o Synthesized high-purity silver and gold nanoparticles using renewable solvents.
o Produced stable copper micro-flakes and nanoparticles with anti-oxidation strategies.
o Created lignin-based hybrid materials with conductive properties using MWCNTs.
2. Innovative Formulations:
o Developed bio-based adhesives with de-bond-on-demand properties.
o Formulated conductive inks with recycled silver and copper nanoparticles.
o Developed high-performance dielectric inks using recycled polystyrene.
3. Digital Printing and Optimization:
o Implemented digital printing techniques for biosensors, reducing material usage.
o Optimized curing and sintering processes, achieving a 20% reduction in curing time.
4. Recycling and End-of-Life Management:
o Developed methods for recycling precious metals from waste PE, achieving a 90.2% isolation rate for silver.
o Investigated biodegradable and recyclable PLA-based substrates, showing >100% elongation.
5. Industrial Demonstration:
o Produced demonstration models for membrane switches and biosensors.
o Tested new sensor designs, reducing gold usage and achieving cost savings.

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)

The SaP project has achieved groundbreaking results:
1. Recycling and Resynthesis:
o Achieved high-purity recycled metal precursors, reducing reliance on mined materials.
o Developed scalable methods for recycling and reusing over 90% of metals in PE.
2. Biodegradable and Recyclable Materials:
o Created fully biodegradable and recyclable PE products.
o Synthesized new PLA-based substrates with enhanced properties.
3. Advanced Digital Printing:
o Demonstrated digital printing technologies that can reduce material usage and curing times.
o Developed high-performance conductive inks using recycled and bio-based materials.