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Flexible Electronics:Revolutionary Products and
Career Opportunities for Creative Engineers
TAPPI - PIMA Student Summit 2011
Michael CiesinskiPresidentJanuary 15, 2011
Flexible, Printed Electronics
•Microelectronics changed theworld by putting intelligence inproducts, enabling many newproducts
•A new field of electronics isemerging which cannot be madesmall, but must be big in order tointeract with big things
•This is flexible, printedelectronics and its salient featureis that it can conform to surfacesto impact a wide range ofapplications
•Opportunities exist for jobcreation and manufacturingdevelopment
2
Lightweight, flexibledisplay from Army/ASU FDC
Printed RFID fromSunchon National Univ.
and Rice Univ.
Konarka’s FlexibleOrganic Photovoltaic
Material
51/27/2011
What is the FlexTech Alliance?
• FlexTech Alliance is a North American organization focused on promoting
the electronic displays and flexible, printed electronics industries.
•The mission of the FlexTech Alliance is to advance
the growth, profitability and success of our member
companies and organizations.
•Our programs are designed to share practical
experience and develop solutions for advancing
displays, flexible and printed electronics, and
related technologies from R&D to commercialization.
1/27/20113
The Vision for Flexible Electronics:An Evolution of Human-Scale Systems
4
• New products and industries– Intelligent medical bandages– Intelligent solar cells– Interactive clothing– Environmental monitoring
Large Flex andDeform
Human-ScaleSystems
Large, Flexible & Deformable – these attributes will enable productsthat are “human-scale” and directly interact with people or the
environment on a large scale!
“Scientific research and technological developments are repletewith examples of breakthroughs that have advanced the frontiersof knowledge, but in themselves do not constitute paradigm shifts.
Flexible electronics, however, represents a highly promisinginterdisciplinary pursuit that will provide greatly increasedfunctionality and the potential to meet future technologicalchallenges.”
5
Dr. Usha VarshneyNational Science Foundation2nd International Symposium in Plastic ElectronicsOctober 2006
The National Science FoundationRecognizes the Potential of Flexible
Electronics
Nanomarkets Forecast 2010 - 2017
6
<$2B
$19B
1/27/2011
OLED $900 million
Photovoltaics $400 million(Excluding CdTe and Conventional Silicon)
Other inks: $400 million
Sensors: $120 million
E-paper displays $100 million
Inorganic Electroluminescentdisplays $60 million
Others $80 million(Batteries, other displays etc)
34% Predominately Printed
18% Flexible
Logic and memory $10 million
The Market Will ShiftBetween 2010 and 2020
Source: IDTechEx
OLED Display & Lighting $19 billion
Photovoltaics $17 billion(Excluding CdTe and Conventional Silicon)
Other inks: $2 billion
Sensors: $1.6 billion
E-paper displays $6 billion
Inorganic Electroluminescentdisplays $0.4 billion
Others $2.75 billion(Batteries, other displays etc)
Transistors: $8 Billion
83% Predominately Printed
75% Flexible
$56.75B$2.1B
11
Challenges Remain In Commercialization
• Obtaining R&D funding
• Developing prototypes
• Transitioning to manufacturing• Cost of initial tooling/ROI• Establishing high volume
production capability• High volume quality
assurance & control
• Identifying future technology and market needs
What is Needed for Flexible Electronics?
1/27/20119
FlexTech fundedR&D in all theseareas
(source: Nanomarkets)
Flexible TFT Array
1/27/201110
Ultra Flexible TFT Array Sheet from Tokyo University
© MeadWestvaco Corporation
Promotes
Entertain
Lights
Sounds
Interactive
Multiple Touch Points
Informs
PromptsResetsRemindsRecommendsHelpfulMotivates
Communicates
ConnectionWired or Wireless
InteractiveUpdatesEase of UsePrograms
Secures
Theft DeterrenceTamper EvidentScreamer TagRFID:Attached tosmart packageAnti-counterfeit
1/27/2011
Smart Packaging Enhances the Customer’sExperience
Flexible Displays
Solid State LightingOLEDs Have a Bright Future
OLED lighting is already beingimplemented in high end automobiles
Other auto makers will follow suit.
Look for more OLED lighting for usein homes as fluorescent bulbs arebeing phased out due to efficiencyrequirements and manufacturersdevelop low cost production techniques.
OLED Lighting
Photovoltaics Provide Plentiful, Clean Energy
Printed solar power is already a reality and is making the movefrom the laboratory into the marketplace – reducing carbonemissions and providing power to remote areas.
Flexible PV
Sensors Are Ubiquitous
Monitor Vital Health Signals•Researchers have created and tested a new type ofimplantable device for measuring the heart’s electrical output.• The device represents the first use of flexible silicontechnology for a medical application.
Track Inventory•One of the world’s largest retailersplans to use electronic ID tags to track clothing.•This is the first step in a system that may better
control inventory.
Integrate Physical and Virtual WorldsTouch technology improves communications,business efficiency, and accuracy of on-screen actions.
1st Movers
Apparel supervisor Sonia Barrett uses a handheld scanner to readEPC labels on men's denim jeans on July 19, while checkinginventory at the Walmart Supercenter Store No. 1 in Rogers, Ark.Wal-Mart Stores Inc. plans to roll out sophisticated electronic IDtags to track individual pairs of jeans and underwear, the first stepin a system that advocates say better controls inventory but somecritics say raises privacy concerns.
East Asia600 Organizations
North America750 Organizations
Europe775 Organization
•Most work in Japan (Koreamoving fast, may overtake)
•Strong government backing inmost aspects
•Few startups but many giantsinvolved
•Defending the massive displaybusiness – buying those in theWest e.g. Eink, CDT etc. (OLEDdisplays, OLED lighting, e-paperetc)
•Developing transistors for displaybackplanes and other applications
•Weak government backingoutside of military
•Many startups involved. Giantsoften slow/unfocussed
•Strong in materials and processdevelopment (inorganic andorganic)
•Usually successfully large usermarket (Amazon Kindle reader,Hasbro/Tink games, skin patches)
•Most effort in Germany. Holland,UK, Sweden also hot
•Strongest government backing inmost aspects (Germany)
•Many large and small companiesinvolved. Few startups
•Strong in materials and processdevelopment (mainly organic)
•Strong in PV manufacture (butloosing ground)
2010 - Trends and Comparisons by Region
Source: IDTechEx
Many Opportunities Exist Within theValue Chain
1/27/201120
Two Paths to Commercialization?
Conformable substrate-Polymer-Metal foil(s)-Glass-Other
Substrate as a system of materials
High performance devices-Suitable substrate-Construct materials-Build prototype tools-Sheet or roll
-Lower processingtemperatures
Good enough devices-Suitable substrate-Identify materials set-Qualify a printing process-Move to R2R
Summary
Why Flexible Electronics?
Form and Fit
Conformable substrates open upenormous application spaces
Textiles, buildings, paper
Cost
Traditional IC lithography andvacuum processing are costly
Mix and match printing R2Rprovides significant savings if thetarget is “good enough”
Ecology
Additive processes vs. removal
Why Now?
Electronics industry alwayssearching for new technology formarkets
Start-up capital available
e.g., Kovio, Novaled, Plextronics
Early adopters available Military, Wal-Mart
High volume consumers seekingideas solutions
Dole, P&G, SmithKline Glaxo
Early results promising
1/27/201122