What does printed electronics say when you bend it? “Stick to your layer!”
In modern product design, engineers and developers often need to mix new technologies with trusted ones. Customer expectations, short deadlines, and limited space make traditional methods hard to use. That’s when printed electronics (PE) becomes useful.
For a designer, PE means adding flexible parts without giving up standard SMD components. For an R&D engineer, it’s a way to try new types of sensors, communication, or power systems. For a product manager, it’s a chance to build thinner, lighter, and smarter products.
But to succeed, you need more than just ideas—you need practical knowledge. How do you mix PE with traditional parts? How do you pick the right materials? How do you design layers that work well together? This article answers common questions, gives tips, and shows examples of real hybrid solutions.
Why Combine PE with Standard Components?
Designers want products that work well, look good, and stay within budget. PE won’t replace every part, but it can:
- Reduce weight and size
- Add new features like flexible sensors or touch panels
- Cut down on wires and mechanical parts
- Improve reliability by removing soldered joints (if designed well)
The main question is: how do you connect PE to classic components like SMD chips, radios, or batteries?
Concern #1: “You Can’t Solder That!”
Printed electronics use low-temperature materials like PET or PEN. These melt at 150°C or less, so normal soldering is risky.
To solve this:
- Use low-temp solder paste (e.g., Sn42Bi57Ag1)
- Try silver-based conductive glue
- Use hybrid assembly: traditional PCB for SMD parts, connected by ZIF cables to flexible PE layers
Tips:
- Plan SMD locations early
- Choose components that work at low heat
- Try “flex-to-rigid” designs (rigid PCB + flexible tail)
Concern #2: “Will It Last?”
Designers worry about bending, moisture, UV, and time. Thin printed layers can crack, peel, or stop working. This matters a lot in wearables, mobile, and medical products.
Solutions:
- Use protective coatings (encapsulants)
- Test bending resistance
- Use double signal paths or backup lines
- Pick strong conductive inks (silver, carbon, graphene)
- For medical use: add soft, biocompatible layers
Concern #3: “We Don’t Know How to Start”
Many teams know classic PCBs well—but PE is new. They don’t want to risk mistakes or extra costs.
Good first steps:
- Work with expert partners (like LC Elektronik, Henkel)
- Use ready-made PE modules (printed NFC antennas, pressure sensors)
- Try small prototypes using PET films and simple tools
- Take courses or read design guides (e.g., “Printed Flexible Electronics Fundamentals”)
Concern #4: “It’s Hard to Estimate Costs or Standards”
In regulated industries (medical, automotive), standards are strict. PE doesn’t yet have clear global norms like IPC or IEC.
Solution:
- Join pilot projects
- Write your own test reports
- Follow groups like OE-A, IPC for PE guidelines
- Work with partners experienced in certified markets
Examples of Hybrid Projects
- Fitness band: flexible heart rate sensor + classic BLE chip, connected with ZIF cable
- Kitchen interface: printed touch surface on glass + PCB for processor and power
- EKG patch: printed electrodes + classic module for battery and data
Conclusion
Mixing printed and classic electronics is not “magic”—just smart design. Plan your layers, use the right materials, and think about real-world conditions. You don’t have to be an expert—just work with the right partners and keep an open mind.
Hybrid electronics give you:
- Flexible sensors
- Smart touch controls
- Lightweight and ergonomic designs
All this—while still using your favorite traditional parts.
Hybrid tech is the future. Try a small project and see how much you can do.
4 Key Points:
- Combining PE and standard parts adds new functions without design compromises
- You can solve connection problems with the right materials and methods
- You don’t need to go alone—get support from expert partners
- The future is hybrid: flexible, modular, smart—and ready for market