Wolfgang Mildner: "The role of flexible printed electronics in automotive applications is growing"
The automotive industry is undergoing a major transformation, driven by the rise of electric vehicles, advanced driver assistance systems and autonomous driving. OPE journal columnist Wolfgang Mildner explores the key applications of flexible printed electronics in the automotive sector and illustrates how they are reshaping vehicle design and functionality.
Flexible printed electronics refers to electronic devices printed on flexible substrates that can be bent, stretched or twisted without losing functionality. These electronics can be integrated into a variety of surfaces and materials, including plastics, textiles and films, making them ideal for automotive applications where flexibility, lightweight materials and space-saving designs are critical.
1. Smart surfaces and touch interfaces
Flexible printed electronics enables the development of smart surfaces and touch interfaces within the vehicle cabin. With the growing demand for intuitive, user-friendly human-machine interfaces (HMI), flexible printed electronics allows manufacturers to integrate touch sensors, capacitive switches and displays directly into the dashboard, steering wheel or even seat upholstery.
Key benefits:
- Enhanced user experience with customisable control panels
- Elimination of traditional buttons and knobs for a sleek, modern interior
- Seamless integration of lighting and gesture control systems
One notable example is the use of flexible OLED displays that can conform to curved surfaces, giving designers the freedom to create immersive digital dashboards. These interfaces can display real-time information, control climate settings and even incorporate haptic feedback for more engaging driver-vehicle interaction.
Printed heating elements and surfaces allow heat to be delivered close to passengers, which is much more efficient, especially, in the case of EVs, where there is no heat from an internal combustion engine.<
2. Lighting and adaptive illumination
Automotive lighting is no longer just about visibility. It has become an essential design element that enhances aesthetics and safety. Flexible printed electronics are being used to create adaptive lighting systems that can be integrated into a vehicle’s body, providing dynamic illumination that adjusts to different driving conditions and environments.
Key benefits:
- Reduced weight compared to traditional lighting systems
- Energy-efficient and environmentally friendly operation
- Customisable lighting patterns for enhanced vehicle styling
Flexible OLED lighting panels, for example, can be embedded or combined with LEDs in the interior or exterior of the vehicle, enabling applications such as mood lighting, responsive ambient lighting or even dynamic brake lights that change intensity based on driving behaviour. These systems improve safety by enhancing visibility while also offering new design possibilities.
3. In-mould electronics for lightweight designs
Weight reduction is a critical factor in improving the efficiency of electric vehicles and reducing fuel consumption in conventional vehicles. Flexible printed electronics (FPE) plays a key role in this by enabling electronic components to be integrated into lightweight, flexible materials. One technique that leverages FPE technology is in-mould electronics (IME).
IME allows electronic circuits and components, such as touch sensors and antennas, to be printed on flexible substrates and moulded into plastic parts during the manufacturing process.
Key benefits:
- Reduces the number of components required, simplifying manufacturing
- Eliminates wiring harnesses, resulting in significant weight savings
- Increases design flexibility, allowing for more streamlined and space-efficient electronic systems
IME technology is often used to integrate electronic controls into components such as dashboards, door panels and centre consoles, reducing weight while maintaining advanced functionality.
4. Wearable sensors for driver monitoring
Another promising application of flexible printed electronics in the automotive sector is the development of wearable sensors for driver monitoring systems. These sensors can be printed on flexible substrates that conform to the shape of the driver’s seat or steering wheel and continuously monitor vital signs such as heart rate, respiration and posture.
Key benefits:
- Enhanced driver safety by detecting signs of fatigue or distraction
- Improved comfort with adaptive seating systems that adjust based on the driver’s physiological data
- Seamless integration into the overall vehicle design without compromising aesthetics
These sensors can connect to advanced driver assistance systems (ADAS), which can alert the driver to potential health risks or adjust the vehicle’s performance based on the driver’s physical state. This real-time monitoring system can help reduce accidents caused by drowsy or distracted driving.
5. Printed tyre pressure monitoring sensors
Tyre pressure monitoring systems (TPMS) are essential for safe and efficient driving. Flexible printed electronics has enabled the development of low-cost, lightweight pressure sensors that can be printed directly onto the inner surface of tyres. More durable and less intrusive than traditional TPMS, these sensors provide continuous, real-time monitoring without the need for complex installation.
Key benefits:
- Reduced maintenance and increased reliability compared to mechanical sensors
- Continuous data collection for predictive maintenance and performance optimisation
- Increased safety by preventing tyre blow outs and optimising fuel efficiency
As well as monitoring tyre pressure, printed sensors can also monitor temperature, wear and even road conditions, providing valuable data for both drivers and vehicle manufacturers.
6. Flexible antennas for connectivity
As vehicles become more connected through 5G networks and vehicle-to-everything (V2X) communications, the need for lightweight, low-profile antennas has grown. Flexible printed antennas offer a solution by enabling integration into curved surfaces such as the roof or bumpers, ensuring optimal connectivity without adding bulk.
Key benefits:
- Improved vehicle connectivity for GPS, 5G and V2X communication systems
- Increased vehicle design freedom as antennas can be hidden within body panels
- Reduced weight and material costs compared to traditional antenna systems
These antennas are essential for autonomous vehicles, which rely on constant communication with infrastructure and other vehicles to navigate safely and efficiently.
Endless possibilities for creating smarter solutions
Flexible printed electronics is transforming automotive design and functionality by offering lightweight, versatile solutions that improve vehicle performance, safety and user experience. From smart surfaces and adaptive lighting to wearable sensors and advanced connectivity, the applications of flexible and printed electronics in the automotive industry are diverse and growing rapidly.
As automotive manufacturers continue to innovate, flexible printed electronics will play a key role in shaping the future of vehicles, offering endless possibilities for creating smarter, more efficient and more sustainable transportation solutions.
Not to be missed: Automotive applications will be highlighted during the LOPEC conference in a new dedicated half-day session.
Caption: The author Wolfgang Mildner is owner of MSWtech in Nuremberg, Germany, fellow of the OE-A and General Chair of LOPEC. (Image sources: LOPEC, ams OSRAM)