2014 2D and 3D printing to realize innovative electronic products
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Most people active in electronics industry are not yet aware that 3D printing can become a game changer. Currently printing and dispensing is done on a limited scale in the electronics industry. For instance: (a) printing of conformal coatings, (b) glob topping of bare dies, (c) dam and fill as packaging technology, (d) dispensing underfill materials, (e) dispensing of conductive adhesives, even dispensing of 3D electrical interconnects. There are three reasons, why printable electronics is gaining considerable attention. The first is that the printing process can be applied to many different kinds of substrates, and also three-dimensional printing is possible. This enables the changing of the whole system of producing electronic devices, including the design and manufacturing phases, material selection, and device structure and architecture. Second, printed electronics offers better economics to electronics manufacturing. Traditional electronics is cheap only on the mass production scale, in contrast to printing, and especially inkjet printing, which offers flexible and cheap production for tailored small-volume products. Third, printing offers new business models. E.g. Inkjet technology enables also ‘‘desktop manufacturing’’, which applies to small-scale micro factories with small fixed costs.
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2014 2D and 3D printing to realize innovative electronic products
- 1. 3D Printing to realize innovative electronic products Jan Eite Bullema
- 2. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 2
- 3. What is 3D Printing? 3D Printing = Additive Manufacturing Layer by layer 3D CAD Slice file Part 3 January 17, 2014 Jan Eite Bullema 2D / 3D Printing
- 4. What is 3D Printing? 3D Printing gives freedom in Product Design January 17, 2014 Jan Eite Bullema 2D / 3D Printing 4
- 5. What is 3D Printing? Additive Manufacturing / TNO achievements January 17, 2014 Jan Eite Bullema 2D / 3D Printing 5
- 6. What is 3D Printing? Additive Manufacturing / TNO achievements January 17, 2014 Jan Eite Bullema 2D / 3D Printing 6
- 7. What is 3D Printing? TNO TECHNOLOGY INSIDE / TNO achievements January 17, 2014 Jan Eite Bullema 2D / 3D Printing 7 Source: TNO 2014
- 8. What is 3D Printing? LEPUS NEXT GEN Large Area / TNO achievements January 17, 2014 Jan Eite Bullema 2D / 3D Printing 8 Source: TNO 2014
- 9. What is 3D Printing? Print Valley 3D Printing / TNO achievements January 17, 2014 Jan Eite Bullema 2D / 3D Printing 9 Source: TNO 2012
- 10. What is 3D Printing? TNO’s Print Valley 3D Printing Machine January 17, 2014 Jan Eite Bullema 2D / 3D Printing 10 Source: TNO 2012
- 11. What is 3D Printing? TNO’s Print Valley 3D Printing Machine January 17, 2014 Jan Eite Bullema 2D / 3D Printing 11 Source: TNO 2012
- 12. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 12
- 13. Methods / Materials / Innovative Electronic Products Major processes for 3D Printing January 17, 2014 Jan Eite Bullema 2D / 3D Printing 13 Source: ASTM International Committee on Additive Manufacturing Technologies Material Extrusion Material Jetting Binder Jetting Sheet Lamination VAT photo Polymerization Powder Bed fusion Direct Energy Deposition
- 14. Methods / Materials / Innovative Electronic Products Additive Manufacturing Processes Powder Bed Selective Laser Sintering January 17, 2014 Jan Eite Bullema 2D / 3D Printing 14
- 15. Methods / Materials / Innovative Electronic Products Quality of 3D Printed Materials Strength of printed metals with OPTOMEC LENS printing Technology January 17, 2014 Jan Eite Bullema 2D / 3D Printing 16 Source: OPTOMEC 2013
- 16. Methods / Materials / Innovative Electronic Products Additive Manufacturing Materials a growing number of printable materials, currently over 200 materials January 17, 2014 Jan Eite Bullema 2D / 3D Printing 17 Source: Wohlers Report 2013 Organic Materials Ceramic Materials Metallic Materials Polymeric Materials Waxes Alumina Aluminium Poly Amide (Nylon) Tissues Zirconia Tool SteelABS Cells Mullite TitaniumPMMA Silicon Carbide Stainless Steel Poly Carbonate GoldPEEK
- 17. Methods / Materials / Innovative Electronic Products Quality of 3D Printed Materials Datasheet SOMOS water resistant resin for Stereolithography January 17, 2014 Jan Eite Bullema 2D / 3D Printing 18 Source: DSM 2013
- 18. Methods / Materials / Innovative Electronic Products Additive Manufacturing Processes Aerosol Jetting Process January 17, 2014 Jan Eite Bullema 2D / 3D Printing 19 Source: Optomec 2013
- 19. Methods / Materials / Innovative Electronic Products Additive Manufacturing Processes Aerosol Jetting Process January 17, 2014 Jan Eite Bullema 2D / 3D Printing 20 Source: Sirris 2013
- 20. Methods / Materials / Innovative Electronic Products Additive Manufacturing Processes Aerosol Jetting Process January 17, 2014 Jan Eite Bullema 2D / 3D Printing 21 Source: Funktionalisierung von Kunststoffen durch Inkjet und Aerosoldruck
- 21. Methods / Materials / Innovative Electronic Products Additive Manufacturing Materials Aerosol Jet Material / Substrate Matrix January 17, 2014 Jan Eite Bullema 2D / 3D Printing 22 Source: Optomec 2013
- 22. Methods / Materials / Innovative Electronic Products Printing used for wiring in aeroplanes January 17, 2014 Jan Eite Bullema 2D / 3D Printing 23 Source: Boeing 2013
- 23. Methods / Materials / Innovative Electronic Products 3D Printed Gaming Die Embedded micro controller and accelerometer identify top surface January 17, 2014 Jan Eite Bullema 2D / 3D Printing 24 Source: W.M. Keck Center for 3D Innovation
- 24. Methods / Materials / Innovative Electronic Products 3D Printing Process: RMPD - mask structure THz antenna with fluidic channel January 17, 2014 Jan Eite Bullema 2D / 3D Printing 25 Source: microTec 2014
- 25. Methods / Materials / Innovative Electronic Products 3D Printing Materials: Meta Materials Meta materials derive their properties not from compositional properties, but from exactingly-designed structures January 17, 2014 Jan Eite Bullema 2D / 3D Printing 26 Source: TNO 2013, TNO 2014
- 26. Methods / Materials / Innovative Electronic Products Process: High Volume Print Forming (HVPF) Printing of fine pitch QFN packages January 17, 2014 Jan Eite Bullema 2D / 3D Printing 27 Source: http://www.eoplex.com/
- 27. Methods / Materials / Innovative Electronic Products Innovative Printed Electronic Products Printing of EMI shielding on a dome January 17, 2014 Jan Eite Bullema 2D / 3D Printing 28 Source: Optomec 2013
- 28. Methods / Materials / Innovative Electronic Products Innovative Printed Electronic Products Assembly-free MEMS Package with Moving Parts January 17, 2014 Jan Eite Bullema 2D / 3D Printing 30 Source: Fraunhofer Gesellschaft 2010
- 29. Methods / Materials / Innovative Electronic Products Innovative Printed Electronic Products Fractal Antenna on Abdomen of a Worker Honey Bee January 17, 2014 Jan Eite Bullema 2D / 3D Printing 31 Source: Wright State University, US Naval Research Laboratory
- 30. Methods / Materials / Innovative Electronic Products Innovative Electronic Products Electronic Tattoo for remote sensing of Patients January 17, 2014 Jan Eite Bullema 2D / 3D Printing 32 Source: University of Illinois at Urbana-Champaign
- 31. Methods / Materials / Innovative Electronic Products Innovative Printed Electronic Products Electronic Tattoo for remote sensing of Patients January 17, 2014 Jan Eite Bullema 2D / 3D Printing 33 Source: University of Illinois at Urbana-Champaign
- 32. Methods / Materials / Innovative Electronic Products Electronic Tattoo for remote sensing of Patients January 17, 2014 Jan Eite Bullema 2D / 3D Printing 34 Source: MIT Technology Review 2013
- 33. Methods / Materials / Innovative Electronic Products 3D Printed Bionic Ear January 17, 2014 Jan Eite Bullema 2D / 3D Printing 35 Source: Princeton University 2013
- 34. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 36
- 35. Rapid Prototyping → Additive Manufacturing The silent revolution in manufacturing of hearing Aid Applications January 17, 2014 Jan Eite Bullema 2D / 3D Printing 37 Source: Widex
- 36. Rapid Prototyping → Additive Manufacturing 2 years time change from manual production to digital shell production January 17, 2014 Jan Eite Bullema 2D / 3D Printing 38 Source: Phonak
- 37. Rapid Prototyping → Additive Manufacturing AM for direct production of parts that end up in final products January 17, 2014 Jan Eite Bullema 2D / 3D Printing 39 Source: Wohlers Report 2012
- 38. Rapid Prototyping → Additive Manufacturing 3D Printing Products / Parts at Home What to print at home: The expanding thingiverse January 17, 2014 Jan Eite Bullema 2D / 3D Printing 40 Source: www.thingiverse.com/ 2013 > 100.000 printable open source designs available on the internet
- 39. Rapid Prototyping → Additive Manufacturing 3D Printing Products / Parts at Home payback time for average US household 4 months to 2 years January 17, 2014 Jan Eite Bullema 2D / 3D Printing 41 Source: Mechatronics 23 (2013) 713–726
- 40. Rapid Prototyping → Additive Manufacturing The emerging Internet of Things is speeding us to an era of nearly free goods and services January 17, 2014 Jan Eite Bullema 2D / 3D Printing 42 http://www.amazon.com/Zero-Marginal-Cost-Society-Collaborative
- 41. Rapid Prototyping → Additive Manufacturing 3D Printing Products / High Volume Electronics Additive Manufacturing Landscape according to Optomec January 17, 2014 Jan Eite Bullema 2D / 3D Printing 43 Source: Optomec 2013
- 42. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 44
- 43. 2D / 3D Printing in Electronics Manufacturing 3D Printing Awareness in Electronics Manufacturing January 17, 2014 Jan Eite Bullema 2D / 3D Printing 45 Source: Global SMT July 2013
- 44. 2D / 3D Printing in Electronics Manufacturing Solder Jetting: mFab printing solder balls on wafer January 17, 2014 Jan Eite Bullema 2D / 3D Printing 46 Source: micro Fab
- 45. 2D / 3D Printing in Electronics Manufacturing Dispensed ‘Wirebonds’ ASYMTEK makes printed wire bond for stacked IC January 17, 2014 Jan Eite Bullema 2D / 3D Printing 47 http://www.nordson.com
- 46. 2D / 3D Printing in Electronics Manufacturing Printed m batteries for integration in m systems January 17, 2014 Jan Eite Bullema 2D / 3D Printing 48 Source: Harvard, 2013
- 47. 2D / 3D Printing in Electronics Manufacturing Printed m batteries for integration in m systems January 17, 2014 Jan Eite Bullema 2D / 3D Printing 49 Source: Harvard, 2013
- 48. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology January 17, 2014 Jan Eite Bullema 2D / 3D Printing 50 Joseph Fjelstad, 2011
- 49. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology The process steps for Occam are few, simple and eliminate the need for solder January 17, 2014 Jan Eite Bullema 2D / 3D Printing 51 Source: Joseph Fjeldstat, Flexible Circuit Technology 4rd Edition
- 50. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology Major process steps for basic surface mount assembly January 17, 2014 Jan Eite Bullema 2D / 3D Printing 52 Source: Joseph Fjeldstat, Flexible Circuit Technology 4rd Edition
- 51. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology Process steps eliminating those made unnecessary by the Occam process January 17, 2014 Jan Eite Bullema 2D / 3D Printing 53 Source: Joseph Fjeldstat, Flexible Circuit Technology 4rd Edition
- 52. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology Relative cost of multilayer circuit constructions and their I/O support capability January 17, 2014 Jan Eite Bullema 2D / 3D Printing 54 Source: Joseph Fjeldstat, Flexible Circuit Technology , 4rd Edition
- 53. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology Assemblies can be interconnected in edge card fashion or in planar fashion January 17, 2014 Jan Eite Bullema 2D / 3D Printing 55 Source: Joseph Fjeldstat, Flexible Circuit Technology , 4rd Edition
- 54. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology January 17, 2014 Jan Eite Bullema 2D / 3D Printing 56 Source: Verdant Technologies, 2007
- 55. 2D / 3D Printing in Electronics Manufacturing 3D Printed Circuit Board / Occam Technology January 17, 2014 Jan Eite Bullema 2D / 3D Printing 57 Source: Joseph Fjeldstat, Flexible Circuit Technology , 4rd Edition Materials costs for the Occam assembly can’t be too much (say 50 cents per, max) and with the elimination of the PCB and Assembly cost, say $2 ($1 for each) that’s a gross savings of at least $100 million annually. The lease rate is probably $100-200k monthly for that $20 million dollar piece of equipment and operations another million (labor, facilities, etc,). So, just off the top, it looks like Occam could save an OEM mobile handset manufacturer 100-150 million $ annually per production line
- 56. 2D / 3D Printing in Electronics Manufacturing Process: Aerosol Jetting OPTOMEC makes aerosol jetting based printed circuit board January 17, 2014 Jan Eite Bullema 2D / 3D Printing 58 Source: OPTOMEC
- 57. 2D / 3D Printing in Electronics Manufacturing Process: Plasma Particle Jetting Flamecon Process January 17, 2014 Jan Eite Bullema 2D / 3D Printing 59 Source: LEONI, 2012
- 58. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes 3D Structural Electronics with FDM and Direct Write Micro Dispensing January 17, 2014 Jan Eite Bullema 2D / 3D Printing 60 Source: W.M. Keck Centre for 3D Innovation, June 2013
- 59. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes 3D Structural Electronics with FDM and Direct Write Micro Dispensing January 17, 2014 Jan Eite Bullema 2D / 3D Printing 61 Source: W.M. Keck Centre for 3D Innovation, June 2013
- 60. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes Printed 3D System in Package January 17, 2014 Jan Eite Bullema 2D / 3D Printing 62 Source: Fraunhofer, 2010
- 61. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes Printed 3D System in Package January 17, 2014 Jan Eite Bullema 2D / 3D Printing 63 Source: Fraunhof IZM, 2010
- 62. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes Printed MID Prototype January 17, 2014 Jan Eite Bullema 2D / 3D Printing 64 Source: Fraunhofer Allianz Generative Fertigung, 2013
- 63. 2D / 3D Printing in Electronics Manufacturing Nano inks enable home printing of electronics within 10 years January 17, 2014 Jan Eite Bullema 2D / 3D Printing 66 Source: Max Planck Institute for Informatics, 2013
- 64. 2D / 3D Printing in Electronics Manufacturing DuPont™ PE510 copper January 17, 2014 Jan Eite Bullema 2D / 3D Printing 67 http://www.dupont.com/products-and-services/electronic-electrical-materials/printed-electronics.html?src=pr-printed-electronics DuPont PE510 Copper Conductor offers cost-effective design flexibility for Printed Electronics
- 65. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes $9k Voxel 8 3D printer to print a drone in your living room January 17, 2014 Jan Eite Bullema 2D / 3D Printing 68 http://gizmodo.com/this-9k-machine-could-usher-in-the-era-of-3d-printed-e-1677580682
- 66. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes $9k Voxel 8 3D printer to print a drone in your living room January 17, 2014 Jan Eite Bullema 2D / 3D Printing 69 http://gizmodo.com/this-9k-machine-could-usher-in-the-era-of-3d-printed-e-1677580682
- 67. 2D / 3D Printing in Electronics Manufacturing Combined 3D Printing Processes $9k Voxel 8 3D printer to print a drone in your living room January 17, 2014 Jan Eite Bullema 2D / 3D Printing 70 http://gizmodo.com/this-9k-machine-could-usher-in-the-era-of-3d-printed-e-1677580682
- 68. 2D / 3D Printing in Electronics Manufacturing IPC is setting standards for Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 71 Source: PCB Magazine August 2013
- 69. 2D / 3D Printing in Electronics Manufacturing IPC is defining standards for Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 72 Source: PCB Magazine August 2013
- 70. 2D / 3D Printing in Electronics Manufacturing IPC is setting standards for Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 73 Source: PCB Magazine August 2013
- 71. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 74
- 72. Recent developments in 3D printed Electronics at TNO 3D Printed Electronic Packaging printed conductive interconnections SLA and LIFT January 17, 2014 Jan Eite Bullema 2D / 3D Printing 75 Source: TNO 2011
- 73. Recent developments in 3D printed Electronics at TNO 3D Printed Electronic Packaging printed conductive interconnections SLA and LIFT January 17, 2014 Jan Eite Bullema 2D / 3D Printing 76 Source: TNO 2011
- 74. Recent developments in 3D printed Electronics at TNO Evaporative Micro Cooling Printing of conformal m fluidic channels January 17, 2014 Jan Eite Bullema 2D / 3D Printing 77 Source: TNO 2011
- 75. Recent developments in 3D printed Electronics at TNO Printing of MEMS pressure nozzles for Melexis January 17, 2014 Jan Eite Bullema 2D / 3D Printing 78 Source: TNO 2012
- 76. Recent developments in 3D printed Electronics at TNO Printing of MEMS pressure nozzles for Melexis After Pressure Cooker Test January 17, 2014 Jan Eite Bullema 2D / 3D Printing 79 Source: TNO 2012
- 77. Recent developments in 3D printed Electronics at TNO Printing of MEMS pressure nozzles for Melexis Packaging of a Ring Resonator January 17, 2014 Jan Eite Bullema 2D / 3D Printing 80 Source: TNO / TUD 2013
- 78. Recent developments in 3D printed Electronics at TNO Printing of micro Fluidic Connectors Printing of m fluidic channels on ceramic substrate and glass substrate January 17, 2014 Jan Eite Bullema 2D / 3D Printing 81 Source: TNO 2013
- 79. Recent developments in 3D printed Electronics at TNO Printing of micro Fluidic Connectors Printing of m fluidic channels direct build on silicon wafer January 17, 2014 Jan Eite Bullema 2D / 3D Printing 82 Source: TNO 2013
- 80. Recent developments in 3D printed Electronics at TNO Printing of micro Fluidic Connectors Printing of m fluidic channels direct build on silicon wafer January 17, 2014 Jan Eite Bullema 2D / 3D Printing 83 Source: TNO 2013
- 81. 3D Printing to Realize Innovative Electronic Products - Content - - What is 3D Printing? - Methods / Materials / Innovative Electronic Products - Rapid Prototyping evolves into Additive Manufacturing - 2D / 3D Printing in Electronics Manufacturing - Recent developments in 3D printed Electronics at TNO - Conclusions: The future of Printed Electronics January 17, 2014 Jan Eite Bullema 2D / 3D Printing 84
- 82. Conclusions The future of Printed Electronics “The Internet of Things” January 17, 2014 Jan Eite Bullema 2D / 3D Printing 85 Source: SMT Magazine • January 2014
- 83. Conclusions The future of Printed Electronics “The Internet of Things” January 17, 2014 Jan Eite Bullema 2D / 3D Printing 86 Source: Nanochip Magazine: January 2014
- 84. Conclusion The future of Printed Electronics 3D Printing of Electronics moves fast ahead January 17, 2014 Jan Eite Bullema 2D / 3D Printing 87 Source: TNO 2012