Challenges of Traditional Electronics

Producing conventional electronic circuits requires huge amounts of energy, complex supply chains, and hard-to-recycle materials. Companies like LC Elektronik, known for quality and stable processes, must adapt their strategies to a new reality in which clients and regulators care not only about technical specs but also about environmental impact.

Karol knew factory operations were increasingly affected by energy prices, and rising transport costs were hurting profits. Shifting part of production to printing technology could mean lower energy use, shorter production cycles, and reduced logistics costs while maintaining high precision.

Printed Electronics: An Eco-Friendly Production Approach

The key difference between traditional and printed electronics is how conductive paths and components are applied. Conventional methods involve complex, high-temperature processes that create waste. Printed electronics use conductive materials like silver or copper, which are applied precisely with low-energy methods.

Main advantages of printed electronics:

Lower energy use – Processes occur at lower temperatures, reducing carbon footprint.  
• Minimal waste – Circuits are built layer by layer, avoiding chemical waste.
• Shorter supply chains – Local production eliminates the need to import components.  

Karol tested printed control panels. The results were surprising: material costs dropped, production time was shortened by 40%, and clients received orders faster.

How to Reduce Carbon Footprint in Electronics Production?

Adopting ESG strategies requires innovative changes to processes and technology. Companies can take these steps: 

• Optimize materials – Choose biodegradable bases and eco-friendly conductive inks. 
• Shorten supply chains – Local production cuts transport-related emissions. 
• Reduce energy use – Printing at lower temperatures slashes energy demand.  

After implementing these changes, Karol saw lower operating costs and more interest from sustainability-focused clients.  

ESG in Practice: Benefits for Companies

Meeting ESG requirements isn’t just about compliance – it brings real business benefits. Clients increasingly choose eco-friendly suppliers, and investors favor companies with lower carbon footprints. 

Benefits for companies using printed electronics:

• Lower costs – Savings on energy and materials. 
• New markets – Access to eco-conscious clients. 
• Better reputation – Increased customer trust.  

A year ago, Karol hesitated about changing technologies. Now, eco-friendly solutions have boosted production efficiency and opened doors to new contracts.

Challenges and the Future of Printed Electronics

Every innovation has challenges. Printed electronics include standardization, startup costs, and material availability. However, the technology is growing in the automotive, medical, and IoT industries.

By collaborating with experts like OE-A and Henkel, LC Elektronik stays updated on trends and offers clients cutting-edge solutions.

Summary

Karol’s story shows that green electronics aren’t a future choice – they’re a necessity for staying competitive. Investing in printed electronics supports sustainable production, cost savings, new clients, and ESG compliance.

Companies that transform can gain financial and reputational benefits. The question isn’t “if” but “when” your company will take this step.

Buying decisions in the electronics industry involves more than checking unit prices. In production companies, the Total Cost of Ownership (TCO) is what really matters. It includes all costs related to using a component—from buying and logistics to its effect on the production line and risks of delays. Indicators like COGS (Cost of Goods Sold), ROI (Return on Investment), or DPP (Days Payable Outstanding) help with planning, but they don’t show hidden costs that can affect the final profit.

Many buyers focus only on direct costs – the price of the part. However, indirect costs – like logistics, production losses, storage, or waste disposal – can raise total costs by 30–50%. In this article, we look at how printed electronics can help save money compared to traditional PCBs, and where the real savings are.

Traditional PCBs – Hidden Costs Often Ignored in Budgets

Many buyers don’t consider the full cost of PCB production and only look at the unit price. But traditional PCBs use a lot of energy and produce a lot of waste, which increases the final cost of the product. Energy prices in Europe keep rising, and production companies already pay 30–40% more than they did 10 years ago.

There’s also the problem of long lead times and complicated supply chains. A standard PCB order can take 6 to 12 weeks to finish, and even up to 16 weeks in busy times. This means companies must freeze money in large warehouse stocks, which causes extra storage costs and the risk of outdated parts.

Traditional PCBs – Hidden Costs That Can Hurt Your Budget

These days, when every cent matters and electronics are changing fast, just looking at the part price is not enough. As a buyer, you know the devil is in the details.

PCBs may look simple, but they can cause big problems. Waste disposal is expensive, deliveries are uncertain, and storing parts cost money. And let’s not forget about defective batches that can stop your production.

1. Energy use and production waste – making PCBs requires chemical processes that create a lot of waste. In Europe, waste disposal costs have risen by 25% in the last five years, and green rules are getting stricter.

2. Long lead times and delays – supply chains are more complex, and transport problems or material shortages can delay delivery by 30–60 days.

3. Storage costs – most suppliers want large orders, so you need space to store them. In Europe, storage costs are 5–10% of the product value each year.

4. Quality issues – bad PCB batches can lead to significant losses. Fixing defects and delays in production can raise the total cost of a part by up to 50%.

Printed Electronics – Lower Operating Costs and More Flexibility

Now let’s look at the other side. Printed electronics – it may sound futuristic, but it’s already here and brings real benefits. First, you use less energy because it doesn’t need high temperatures like traditional PCBs. That already saves money.

And what about waste? No chemical baths – you only print what you need. Logistics is easier too – no more waiting for containers from the other side of the world. You print locally when required and save on storage and transport costs.

Flexibility is key today, and printed electronics gives you exactly that.

1. Lower energy use – printed parts use less heat, cutting energy costs by 30–40%.
2. Less waste – printing layers exactly where needed removes the need for chemical etching and reduces waste by up to 90%.
3. Shorter supply chains – local production means no need for long-distance shipping, which cuts transport costs by 20–25%.
4. On-demand production – print when needed, no big stock, no risk of outdated parts.

TCO Analysis: PCB vs. Printed Electronics

So how do things look when we compare traditional PCBs with printed electronics? At first, PCBs might seem cheaper for big orders. But for smaller volumes, printed electronics can be more cost-effective. Plus, printed components use less energy and waste fewer materials. And supply chains? We all know the pain of waiting for a shipment from far away. With printed electronics, you produce locally and avoid the risk.

And most important – flexibility. Want to change the design? Just print new parts – no need to worry about old stock sitting in storage. In today’s fast-moving world, that’s priceless.

1. Purchase cost – PCBs may be cheaper per unit in large orders, but printed electronics are better for smaller batches.
2. Operating cost – printed parts use less energy and fewer raw materials, which matters over time.
3. Risk costs – local production and simpler supply chains reduce delays and production stops.
4. Production flexibility – easily adapt components to your needs without large orders, perfect for low-volume production and prototyping.

What Will Affect TCO in the Future?

What’s next? Because let’s be honest – we don’t live in a bubble. Environmental laws, EU rules about recycling and CO₂ emissions – these are real. Big changes are coming by 2030. Traditional PCBs could get more expensive. Add rising energy prices, and it’s clear the future favors energy-saving tech.

And supply chains? One problem on the other side of the world can stop everything. Customers also want more eco-friendly and flexible products. If we don’t give them that, they’ll go to someone who will. So it’s time to plan for future TCO costs – look for solutions that are cheaper and greener. Or else… we’ll be in trouble.

1. Environmental laws – by 2030, the EU will make recycling and CO₂ rules stricter, which may raise PCB costs.
2. Energy prices – global energy prices are rising, and PCB production is energy-heavy.
3. Logistics issues – geopolitical tensions and raw material shortages increase the risk of delays. Local production will become more attractive.
4. Market trends – customers expect green, flexible solutions, and that affects which suppliers they choose.

Conclusion

TCO analysis is key in electronics purchasing. Traditional PCBs may look cheaper in the short term, but long-term costs, delivery risks, and environmental impact can raise their true cost. Printed electronics, thanks to lower energy use, less waste, and more flexibility, are becoming a competitive option. With rising energy prices and new regulations coming, companies must include full TCO when making investment decisions.

Choosing the right production technology for electronic components is crucial for final quality, costs, and process efficiency. For engineers, deciding between Roll-to-Roll (R2R) and Sheet-to-Sheet (S2S) methods isn’t just about speed – it also depends on technical limits and material requirements. Each method has unique uses, and the choice should be based on a detailed analysis of your project’s needs.

Roll-to-Roll (R2R) Technology – When to Choose It?

Roll-to-Roll is a continuous production process where materials are applied to a flexible roll, then wound up. It’s ideal for large-scale production, especially for flexible printed circuits (FPCs), OLED displays, sensors, and thin-film solar cells.

Advantages of R2R:

1. High Efficiency and Scalability

   R2R can achieve production speeds of 50–100 meters per minute, making it perfect for mass production of consumer electronics or advanced technologies like RFID tags and biosensors.

2. Lower Costs per Unit
   For large orders, R2R significantly reduces costs. Less material waste and the ability to print multiple layers in one cycle improve cost efficiency.

Limitations of R2R:

1. Complex Quality Control and Equipment Costs
   R2R requires precise tension control of the roll, leading to high initial investment in production lines. Some materials, especially less flexible ones, are harder to process.
2. Material Resstrictions
   R2R needs flexible substrates like polyimide (PI), PET, or PEN. This method is less practical for rigid PCBs.

Learn more about R2R materials on manufacturer websites:

• Henkel Printed Electronics
• Heraeus Printed Electronics

Sheet-to-Sheet (S2S) Technology – Precision and Flexibility

Sheet-to-Sheet applies materials to individual sheets, processed step by step. It’s ideal for small batches, prototyping, or applications needing high precision.

Advantages of S2S:

1. Highest Precision
   Sheets can be processed with tolerances as tight as ±5–10 µm. This is key for high-end sensors, microelectronics, or embedded systems with strict technical requirements.
2. Qider Material Options
   Unlike R2R, S2S works with rigid or unusual substrates like ceramics, glass, or FR4 PCB, which can’t be processed on rolls.

Limitations of S2S:

1. Lower Efficiency
   Handling individual sheets reduces speed compared to R2R, raising costs for large orders.
2. Limited Automation
   Many S2S processes require manual work, increasing error risks and affecting repeatability for big projects.

Find S2S printing materials here:

• Elantas Printed Electronic Products

Technical Tips – Printing Process Differences

1. Screen Printing vs. Inkjet Printing
   
   • Screen printing (used in R2R) applies thicker layers (over 10 µm), ideal for conductive paths.
   • Inkjet printing (used in S2S) creates ultra-thin layers (under 1 µm), perfect for high-precision tasks.
   • At LC Elektronik, we combine both methods.
2. Drying and Curing
   
   • R2R uses UV or IR systems for fast curing.
   • S2S often uses thermal drying for better material adhesion. We use all methods: thermal, IR, and UV.
3. Flexible vs. Rigid Substrates
   
   • Flexible R2R substrates may increase resistance, affecting high-frequency circuits.
   • Rigid S2S substrates (ceramics, metal) offer low impedance and mechanical durability.

Summary – Which Method to Choose?

Your choice depends on the project. If you need precision, material variety, or design flexibility, choose S2S. R2R is better for mass production and lower costs.

At LC Elektronik, we specialise in Sheet-to-Sheet technology, offering precise solutions for unique client needs. Contact us to discuss your project or find the best method for your application – we’re here to help!

Electronics production is a bit like managing a Formula 1 team – speed, precision, and flexibility decide success. Every project manager knows that even the best-planned project can go wrong because of unexpected problems. Lack of components, design mistakes, wrong materials – all of this can mess up your timeline like an Excel sheet after accidentally deleting a few columns.

So, how do you avoid wasting time, money, and nerves? Here are five common traps project managers in small and medium production companies fall into.

Trap 1: The Magic of New Technologies – Shiny ≠ Better

Every year, the electronics industry introduces new materials and super-efficient processes and promises that everything will work faster, better, and cheaper. Graphene-based semiconductors? Printed solar cells? These ideas sound great, but first, ask yourself: Can your team use this without delays?

How to avoid it?

There’s nothing wrong with testing new things, but prototyping is key. If a new material or process needs rebuilding the production line or complex training, savings may come only after years. Start small, test in real conditions, and read industry reports.

How LC Elektronik can help:

We can run compatibility and durability tests in our lab to see if the material really fits your needs.

Trap 2: Old Materials? Must Be Outdated!

In electronics, “new” doesn’t always mean “better.” Polyimides, PET films, or traditional conductive inks are still used a lot – especially where stability, availability, and predictable costs matter.

How to avoid it?

Before you choose a new high-tech composite, check if it really gives any advantage. Sometimes the differences are small, or the new material might even be less durable or more sensitive to the environment.

How LC Elektronik can help:

We compare materials for you, evaluating cost, durability, and ease of use. This helps avoid problems with availability or changes late in production.

Trap 3: Design Inflexibility – “We’ve Always Done It This Way”

Designing electronics is not only about looks and function – it’s also about what’s possible to produce. A complicated design or unusual parts can make assembly a nightmare.

How to avoid it?

Decide which design parts are truly important and which can be simpler. Adjusting the design to match machine and supplier capabilities lowers costs and makes production more predictable.

How LC Elektronik can help:

We work with engineers and PMs during the design phase to optimize construction for production cost and scalability.

Trap 4: “Small” Problems? Nobody Will Notice…

A 1mm error on a touchscreen can make it annoying for users. A badly printed conductive layer might cause micro-cracks and failures. The problem seems small, but in mass production, it can mean thousands of returns and expensive fixes.

How to avoid it?

Don’t assume that small mistakes are okay. Test in real conditions, check standards, and analyze quality control results.

 Example: NASA allows tolerance of just 5 micrometers in some space projects – because even tiny errors can lead to failure in extreme conditions.

Trap 5: “I Don’t Trust Anyone – I’ll Check Everything Myself”

As a PM, if you try to do everything – schedules, quality, logistics – you will become a bottleneck. Not delegating leads to chaos and delays.

How to avoid it?

Build a team that works independently and feels responsible. Delegating doesn’t mean losing control – it increases efficiency and avoids burnout.

Tip: PMs who use regular retrospectives and feedback sessions lower the risk of mistakes by 20–30%. People spot issues more easily when they’re part of the decision-making process.

Summary: Your Projects Can Be More Predictable

A PM in electronics is not just a person with a schedule – they’re a strategist. You can’t plan for everything, but you can avoid risk by not falling into these traps:

✅ Test new technologies, but start small
✅ Don’t ignore proven materials just because they’re old
✅ Design with flexibility and production reality in mind
✅ Don’t underestimate small issues – they can grow into big problems
✅ Delegate and trust your team – you’re a manager, not a micromanager

Managing risk in electronics production is a balance between innovation and stability. The key is knowledge and making decisions based on real data. This way, you avoid surprises and make your project more competitive.