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

Periodic Reporting for period 3 - LEE-BED (Innovation test bed for development and production of nanomaterials for lightweight embedded electronics)

Okres sprawozdawczy: 2022-01-01 do 2023-06-30

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.
At M54, end of the project, all of the main objectives and milestones have been achieved.

Highlights of the results achieved are:

All deliverables have been submitted. Alle milestones have been achieved on time.

LEE-BED has made a rebranding to facilitate market penetration going forwards. A new single entry point website has been launched, called SUSTAINATRONICS and can be accessed at www.sustainatronics.eu.
An aggressive outreach strategy has been implemented, resulting in over 65 contributions to events, over 40 on-line publications and 7 peer review publications, with several still under development. Finally, due to an aggressive Linked-In campaign, with over 130 posts, LEE-BED’s company profile has over700 followers.

In total over eight support services have been developed and tested on the both internal industrial LEE-BED end user cases and external end users, with a high success. These are now commercially available through the Sustainatronic SEP website.
All nanomaterial pilot lines have been upgraded and validated, demonstrating development under 3 months of novel silver nanowires, upscaling nano copper production to over 10kg per day and production of tailored 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, zinc based ink-jet and screen printable inks dedicated to a R2R and S2S print pilot line. It has been demonstrated that a functional formulation can be developed below 2 months, which is a substantial improvement compared to before the project, which took typically over 6 months.

Final demonstrators, for internal LEE-BED end users, using upgraded pilot lines, have been finished, 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 glass composites and embedded touch and LED lighting into injection molding plastic parts.

The open call for taking in external industrial end user into LEE-BED has been performed successfully. In total 13 external companies, have received support services and five external companies, have received pilot projects. Through these projects, it was also demonstrated the ability to go from idea to first prototype, within 6 months, which is a major achievement. LEE-BED has demonstrated the ability to support SMEs with fund raising, which has resulted in a commercial turnover of over 90.000 €, before project end.

A clear and straight forward business plan has been formed around the Sustainatronics SEP, which will bring both new commercial R&D collaborations among the LEE-BED partners in the coming years.
Beyond SoA is achieved through upgrading pilot lines for

rapid development of nanomaterials under 2 months
direct writing of novel nanomaterials onto surfaces for rapid prototyping and sensor development
up scaled production of nanomaterials, producing over 10kg nanoparticles per day
high throughput screening of nanomaterial based formulations, achieving development times below 2 months
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
development time from idea to component prototype below 6 months

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