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Innovation test bed for development and production of nanomaterials for lightweight embedded electronics

Periodic Reporting for period 2 - LEE-BED (Innovation test bed for development and production of nanomaterials for lightweight embedded electronics)

Berichtszeitraum: 2020-07-01 bis 2021-12-31

Conductive, dielectric and semiconductor inks and composites are main constituents of the LEE-BED markets, which are exhibiting strong growth and are predicted to reach almost USD 8 billion by 2018 and USD 14 billion by 2027 . There is a strong push towards using nanomaterials instead of micro-material based pigments, due to superior electrical performance, lower processing temperatures and reduction of material consumption . This will allow cheaper, more versatile and sustainable integration of electronics into products. Furthermore, the digitalisation of the European production industry (Industry 4.0) through digital based production technologies, such as ink-jet printing, additive manufacturing, robotically assisted in-mould labelling, laser processing and stereo lithography requires functional nanomaterials and formulations, and the availability of these nanomaterials is a major bottleneck , which LEE-BED will resolve. The main barriers for nanomaterials penetrating the embedded/printed electronics industry are: (1) long development times for materials and formulations, typically over six to nine months each, (2) high costs due to long development times as well as limited volume production for nanomaterials, (3) lack of validated digital pilot lines for production at industry relevant volumes and (4) lack of underpinning metrologies and quality standards.
The ambition for LEE-BED is to eliminate these barriers and offer solutions to European industry through a full service from concept to pilot production of prototypes. LEE-BED will have of a single entry point (SEP) attracting European enterprises through three key phases, consisting of (1) a techno/economic assessment, including life cycle analysis, patent mapping and safety/regulatory review, (2) a pilot project using existing and upgraded pilot lines and (3) knowledge transfer, including intellectual property rights (IPR) and patent assessments, standards/safety screening and access capital investment opportunities. LEE-BED will bring together and upgrade pilot line facilities across the entire value chain from (a) production of functional nanomaterials to (b) formulation of tailored inks, adhesives and composites, and to (c) digital production of light weight smart components with embedded electronics. The result will minimise concept to prototype to below six months, minimise resources and costs and promote keeping manufacturing industry within Europe. LEE-BED’s main focus will be rapid development and pilot production of nanomaterials, composites and formulations for 2D and 3D printing of embedded electronics using scalable processing techniques.

The overall objectives are:

Ensure LEE-BED sustainability
• Minimise concept to prototype to below six months.
• Bring over 100 new stakeholders into the already large LEE-BED community through targeted outreach activities.
• Create a user-friendly/interactive web-based single entry point (SEP)
• Develop economic support services to SMEs for LEE-BED services and pilot lines through public and private funding schemes
• Demonstrate the ability to provide a turnover of over €40 M (four times EU funding) within five years after project end

Provide LEE-BED users full techno/economic assessment services
• Develop technological assessment and modelling services
• Develop end-to-end life cycle analysis (LCA) services
• Develop business canvas modelling services
• Develop patent mapping services
• Develop safety & regulator assessment

Provide LEE-BED users upgraded pilot lines across entire value chain
• Upgrade five nanomaterial pilot lines for metallic, oxide, ferromagnetic and hybrid carbon nanomaterials
• Upgrade four formulation pilot lines for inks, adhesives and composites
• Upgrade four digital pilot lines for printing and assembling embedded electronic components

Provide LEE-BED users post project support
• Develop IPR and patenting consultation services
• Develop up-scaled process economic modelling based on ERP and MRP concepts
• Screening and development of regulatory and safety standards
• Acquiring and linking investment capital instruments for full production infrastructure development
At M36, almost 75% into the project, lots of work has been achieved. The main results achieved thus far are:

The final LEE-BED website, containing the single entry point (SEO) has been established and upgraded to accept submissions of LEE-BED clients.
An aggressive outreach strategy has been implemented, resulting in over 40 contributions to events and over 550 followers on LEE-BED's linked in company profile.
Five services have been developed and tested on the four industrial LEE-BED end user cases with a high succes.
All nanomaterial pilot lines have been upgraded and validated, demonstrating development under under 3 months of novel silver nanowires, upscaling nano copper production to over 10kg per day and production of taylored nanomaterials that have been directly written onto substrates demonstrating novel gas detection.
All nano enabled formulation pilot lines have been upgraded and validated, involving rapid development of copper and silver based inks and zinc based ink-jet and screen printable inks dedicated to a R2R ink jet pilot line.
Final demonstrators, for internal LEE-BED end users, using upgraded pilot lines, have been fnished, demonstrating for interactive touch & lighting solutions, transparent touch and LED paneling, 3DMM printed rings with touch, LED and ECG functionalities, CO2 sensing using color changes, temperature & humidity logging on labelling substrates, embedded asset tracking and passive temperature sensors into fiber glas composites and embedded touch and LED lighting into injection moulding plastic parts.
The open call for taking in external industrial end user into LEE-BED has been performed and over 5 phase 1 cases have been started.
Second preliminary market assessment, including PESTLE, SWOT, Porter's Five Forces, and Business Model Canvas have been performed, in order to ensure LEE-BED sustainability post project.
Beyond SoA is achieved through upgrading pilot lines for

rapid development of nanomaterials
direct writing of nanomaterials onto surfaces
up scaled production of nanomaterials
high throughput screening of nanomaterial based formulations
up scaled production of inks, adhesives and composites
rapid component prototyping with digital ink jet printing
digital R2R production of printing components
3D multi material printing of embedded electronic pilot line
R2R Quality control test line
R2R laser micro-machining production line
Implementation of non destructive quality control for all pilot lines

Stream lined single entry point, for easy access for customers to gain access to services and pilot lines.