Amro Abu Zarour, Beneli: The role of printed electronics in the evolution of wearable technology
The wearable technology industry has grown rapidly over the past decade, evolving from simple fitness trackers to advanced health monitoring devices and smart clothing. At the heart of this evolution is the field of printed electronics, which offers innovative solutions to the unique challenges of wearables, says Amro Abu Zarour, Project Manager at Beneli in Helsingborg, Sweden.
The article was first published in OPE journal 47. You can find the epaper under the following link: OPE journal
Wearable technology refers to electronic devices worn on the body, often incorporating sensors to monitor various physiological parameters. From early wristwatches and pedometers, wearable devices have evolved into sophisticated tools that can track heart rate, sleep patterns and even detect early signs of disease.
Printed electronics is the process of creating electronic devices by printing conductive materials onto various substrates. This process is particularly suited to wearables because it can produce flexible, lightweight and stretchable electronic components that can conform to the human body.
Trends in wearable technology
One of the major trends in wearable technology is the integration of health monitoring features. Devices with heart rate monitors, electrocardiograms (ECGs) and blood oxygen level sensors are becoming increasingly common. These features provide users with valuable health insights and can even alert them to potential health issues in real time.
Advances in printed electronics for wearables have significantly expanded the possibilities for wearable technology. The development of flexible and stretchable materials, innovative conductive inks and substrates and the integration of nanotechnology have improved the functionality, durability and comfort of wearable devices. New printing techniques are also enabling the precise and scalable production of these advanced components. Roll-to-roll (R2R) manufacturing is a key process in achieving this scalability, facilitating the continuous production of flexible electronic components. As research and development continues, the future of printed electronics in wearable technology looks promising, with the potential to transform the way we interact with and monitor our health and environment.
Industry collaboration is essential to drive innovation. Partnerships between tech companies, research institutions and healthcare providers are driving the development of next-generation wearables. These collaborations are critical to overcoming technical challenges and bringing new products to market.
Printing techniques for printed electronics
A variety of printing techniques are used for printed electronics in wearables. Inkjet, screen and flexographic printing allow the precise deposition of conductive materials onto flexible substrates to create intricate circuits.
Screen printing is ideal for flexible substrates due to its versatility and ability to handle different conductive inks. It offers high throughput, meets high volume requirements and works well with substrates such as PET, PU and TPU, ensuring strong adhesion and reliable performance. It also minimises waste by using only the ink needed, making it economical and environmentally friendly. Scalable and cost-effective, screen printing is suitable for mass production.
In summary, screen printing’s versatility, scalability, high throughput, design flexibility, compatibility with flexible materials, durability and efficiency make it ideal for producing high-performance, flexible electronic components for wearable technology.
Wearable patches: differences and advantages
Consumable wearable patches represent a unique and rapidly growing segment of the wearable technology market. Unlike traditional wearables, these patches are designed for short-term use and are often disposed of after a single application. They are typically made from flexible materials and incorporate printed electronics to achieve their functionality.
One of the main advantages of consumable wearable patches is their convenience. Users can simply apply a patch to their skin to monitor specific health metrics without the need for bulky devices. These patches are clinically tested to ensure safety and reliability. They are particularly useful where continuous monitoring is essential but traditional wearables are impractical.
The development of consumable wearable patches has been greatly facilitated by advances in printed electronics. The abili-ty to print complex electronic circuits onto flexible substrates enables the creation of highly functional yet disposable devices. In addition, the use of biocompatible, medical grade materials ensures that these patches are safe for direct skin contact.
Med-tech wearables and consumer wearables
Med-tech wearables and consumer wearables differ significantly in their intended use, regulatory requirements and precision. Med-tech wearables must meet rigorous standards set by bodies such as the FDA to ensure safety and efficacy. They undergo extensive clinical testing, including laboratory testing, patient trials and post-market surveillance.
Manufacturing is subject to strict quality controls, good manufacturing practices (GMP) and regular inspections. Even after approval, these devices are monitored for safety and efficacy, with mandatory reporting of adverse events and potential recalls.
Med-tech wearables provide highly accurate and reliable data that is critical to medical diagnosis and treatment. Consumer wearables, while aiming for accuracy, may not meet medical standards. They track general health metrics such as steps and heart rate to help users achieve fitness goals. While consumer wearables focus on lifestyle improvements, med-tech wearables focus more on medical improvements.
A rapidly growing market
The evolution of wearable technology from simple fitness trackers to sophisticated health monitoring devices and smart clothing has been driven by advances in printed electronics. This field has enabled the creation of flexible, lightweight and stretchable electronic components that are essential for wearable devices. Printed electronics has expanded the possibilities for wearable devices, improving their functionality, durability and comfort through innovations in materials, conductive inks and substrates.
The wearable consumable patch segment is a rapidly growing part of the market. These patches offer convenience, comfort and non-invasiveness, making them ideal for continuous health monitoring without the bulk of traditional devices. The market for these patches is expected to grow significantly, driven by advances in health monitoring technologies and increasing consumer acceptance.
About Beneli
Beneli, headquartered in Helsingborg, Sweden, is an innovative contract manufacturer of printed electronics and complex adhesive applications with high quality requirements. Beneli develops and supplies converted adhesive solutions to the world’s leading medical companies and produces near-body, wearable sensor patches that are revolutionising the healthcare sector.
The author
Amro Abu Zarour is an experienced Project Manager with extensive experience in supplier management and printed electronics. Known for his structured, goal-oriented approach, he excels at managing multiple projects and fostering effective collaboration with diverse teams. Currently, he is leading several projects with new R&D initiatives and their transition to mass production in the healthcare sector, keeping abreast of the latest technologies.
Caption 1: Scalable and efficient: a roll-to-roll (R2R) manufacturing setup in Beneli’s factory, showing the continuous production of flexible electronic components; Amro Abu Zarour, Beneli.
Caption 2: Small and sleek: a conceptual, innovative, wearable and stretchable printed electronics patch for stick-to-skin medical applications. (Image source: Beneli)