3d printing solutions for the electronics industry

L’innovation

Of 3D printing in the electronics industry

Just like in any other field, additive manufacturing (AM) also offers unique opportunities in electronics. Its ability to combine multiple materials into individual print jobs is very useful in this industry. 3D printing technologies are much more accessible and simple than they were previously. This allows for significantly faster prototyping, which could reduce lead times, costs, and errors that disrupt the manufacturing process.

When to choose 3D printing for electronics

For on-demand production

3D printing enables the on-demand production of an electronic part with fixed lead times and a low cost structure, which significantly reduces the time it takes to design and launch a product. It also makes it easy to produce new and old devices with multiple 3D printing materials and low volumes directly from a manufacturer’s digital inventory or a customer’s CAD model.

This is the main advantage and will transform the electronics supply chain and enable manufacturers to meet customer demand instantly.

For more innovation and customization

There are many possibilities for designers to come up with innovative ideas instead of using the same traditional designs due to the complexity of new and efficient designs. SLS and MJF technologies are also valid for complex designs and also for batch production, which was previously a disadvantage of AM. A good batch size of electronic enclosures, breadboards etc can be produced very quickly with AM, compared to conventional processes.

For example, using 3D printing for solar panels helps designers break conventional design rules. This means not only the external structure, but also the internal circuitry that could help improve component performance, minimize size, optimize weight, and achieve complex and precise geometries.

For faster prototyping

The speed and ease of use associated with additive manufacturing make it ideal for creating rapid prototypes. Printing parts with Multi jet fusion (MJF) is a relatively inexpensive option often chosen for prototyping.

Fused deposition modeling, the most accessible form of additive manufacturing, is another viable alternative. FDM is the cheapest and best technology for prototyping due to its simplicity of use and cheapest construction material. Since the entire process is much cheaper than conventional processes, there are greater chances of redesign and analysis in a short amount of time.

Have new materials to experiment with

Electronic products such as PCBs mainly depend on two types of materials: an insulating dielectric substrate and conductive elements. Newer polymer materials with low dielectric constant and semiconductor polymer materials, both with adjustable electronic properties, have been adapted for use in recent times. These advanced materials, coupled with 3D printing, can open new doors in terms of modern design and developments.

To achieve parts with a good surface finish

Technologies such as SLA or DLP use resin materials and are fluidic in nature and offer a good surface finish. They offer properties such as flexibility and water resistance, which are a valuable addition to modern electronics such as foldable phones and water-resistant gear. If the primary need is tight tolerance and precision, these two are the technologies to keep an eye on.

Benefits of Additive Manufacturing in Electronics

Correct and optimized design

Because the model is computer generated and printed, there is only a small margin of error. In a traditional process, the circuit is added to the complete part in the next step, but in the additive process, the constructed circuit is printed together with the part causing the circuit to encapsulate within it, safeguarding the circuit from external damage. For example, the small antenna of a mobile phone can be printed directly into a phone.

Printing on non-flat surfaces

Electronics such as PCBs can simply be 3D printed on non-flat surfaces, while conventional methods do not allow for this process. Similarly, electronics can be easily incorporated into wearable devices, sensors on flexible surfaces, sugar test strips, prosthetics, and customizable batteries.

Custom devices and 3D printed batteries can outperform regular ones as their shapes and sizes are customized to fit a particular product and function, thus optimizing performance.

Lightweight and less material waste

One of the significant features of 3D printing is that it produces less waste than conventional subtractive processes, and the same is true for electronics as well. 3D printing eliminates the need for additional wiring and circuitry. In addition, printed electronics eliminate the steps involved in conventional manufacturing in a single step, thus facilitating even easier assembly.