PrintoCent in Oulu, Finland - Commercializing Printed Intelligence … · 2019-09-01 · Materials, process, components - lntegration to Products/Market Building the Pilot Infrastructure

Ilkka KaistoPrintoCent, Director

VTT, Printed Functional Solutions

PrintoCent – enabling commercializationof OLAE in Roll-to-Roll manufacturing

PrintoCent in Oulu, Finland - Commercializing Printed Intelligence

224/07/2013

Copyright VTT

VTT Center for Printed Intelligence in brief (100 persons)

Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging

Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps

Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging

Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps

Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing

Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing

Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization 2010-- Pilot Factory 2012

R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration

Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization 2010-- Pilot Factory 2012

R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration

VTT Printed Intelligence 2012 | For external use

The vision is to create easy to use and cost effective products based on sensing, light emitting surfaces, energy foils, optical films and electrical circuits by using printing methods.

VTT GROUP: Turnover 307 M€ (2011) • Personnel 3,187 (31.12.2011)

Read more atwww.vtt.fi

324/07/2013

VTT sites on the globe

SiliconValley,

USA

Saint Petersburg,

Russia

Brussels, Belgium

• •• •

•

Tampere

Oulu

Jyväskylä

Espoo

Lappeenranta

••Turku Rajamäki

• Raahe• Kajaani

Kuopio•

Shanghai, China

Seoul, South Korea

Tokyo, Japan

Finland

424/07/2013


Content of Presentation

Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics

Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products/Market

Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll

Industry Cluster pilots 2013-2015Market trials - towards 100.000 pcs in 24h

No more far away!The emphasis of international economy and politics has moved towards north

No more far away!The emphasis of international economy and politics has moved towards north

A long history of creating centre for the world-class research and development

A long history of creating centre for the world-class research and development

The area is a development centre of northern Europe and a hub of northern potential

OULU

Since 2005 the Nokia Cluster: -- 5000 jobs,

mainly on mobile phonesDevelopment & Manufacturing

`Oulu has to find something new`

624/07/2013

Regional Perspective – City of OULU

Free labour force:International, Industry Experienced

Big company oriented – EntrepreneurshipCompetence: Product Design, Development & Manufacturing

Actions taken:Takomo - > 60 companies since 2010

Starttaamo - > 10 M€ vc money Business Kitchen 2012 - > Activation of students

Accelerator - > 90 days boot camp

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Regional Perspective – City of OULUUniversity of Oulu 17.000 students,

Oulu University of Applied Sciences 8000 students

OIA - Oulu Innovation Centers of Excellence

CEE

Centre for Environmentand Energy

CIE

Centre for Internet

Excellence

MAI

Martti Ahtisaari Institute

PrintoCentCenter for

Printed Intelligence

CHT

Centre for Health and Technology

Introduction to printed electronics’New’ revolution in electronics:

1900 1950 2000

Printed TransistorTransistorVacuum tube triode

Radio in every house

Computer on every desk

Electronics everywhere

1906 19

47

2001

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VTT Printed Intelligence

Project modelate 90s - 2005

Strategic research Program

2006 – 2009

CommercializationStage, 2010-Phases

Strong EU-project portfolio created10 10040

Machines

Pico 2003 ROKO 2007 Pilot production MAXI 2012

Major references

Marketing theme

Roll-to-Roll Roll-to-Product Roll-to-Revenue

MetsoAvantone

BASF, Nicanti, UPMOrion Diagnostica

>10 start-up companies established

Productexamples

Orion DiagnosticaCleanCard PRO®

Iscentholographic foil

BASF materials for printed electronics

People

TechnologyMarkets

SystemsProducts

Solutions1

10

100

CHALLENGE:“There is currently a disconnect between the technology supplier and us the end users.”

Pilot factory”-services

R&D & Innovationservices

Killer Applications

Picture copyright: VTT

1224/07/2013







Introduction to printed electronics

Wetting properties are needed to modify and control in printed electronics!

Inkjet-printer

Precis and accurate deposition on solution based materials is very challenging and it requires deep understanding of wetting phenomena.

Printing methods

Principle of printing methods

Printed electronics can utilize any solution-based material, including organicsemiconductors, inorganic semiconductors, metallic conductors, nanoparticles,nanotubes, etc.

Introduction to printed electronics

Roll-to-roll manufacturing method enables to reduce mass production costs of printed electronics.

Schematic of MEIS structure fabrication in roll-to-roll

Introduction to printed sensors

Printing manufacturing requires multidisiplinary team work:

Printed sensor manufacturing needs number of different materials with completelydifferent properties, but compatible with each other.

• Conductors, semiconductors, dielectrics, functional polymers• There is several commercially available inks.

Custom made ink formulation often is required!

Chemistry Engineering

Physics

Encapsulation

Substrates

Raw materials and inksC

HALLENGES

Processing

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Solution processable materialsSolution processable materials

Non-vacuum roll-to-roll manufacturing processesNon-vacuum roll-to-roll manufacturing processes

Components, system integration, end products

Printed Intelligence

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Printed electronics vs. traditional graphical printing

MODIFICATIONSMODIFICATIONS

Separated dotsHigh uniformity requirements

P. Kopola et al., Solar Energy Materials and Solar Cells. Vol. 94 (2010) No: 10, 1673 - 1680 P. Kopola et al., Thin Solid Films. Vol. 517 (2009) No: 19, 5757 - 5762 0 1 2 3 4 5 6 7 8 9 10

0

1

2

3

4

5

Cur

rent

den

sity

[mA

/cm

2 ]Voltage [V]

PEDOT Modified PEDOT

Organic and Large Area Electronics, Printed Intelligence, Printed Electronics

Challenge is how to create products !

Printed passive components 7-segment OLED display Solar energy module Printed memory (WORM)

Hot embossed microfluidistics OLED element Biobattery Printed low-cost indicators

R2R printed Aluminium ink In-mould OLED element

R2R processed OPV foil Opto-fluidic sensor with light source Wide area sensor matrix Active paper

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Ubiquitous Sensing and DiagnosticsEat a sensor …..

…wireless communication to a reader

Proteus Digital Health Feedback System; tablet/chip(ingestible sensor) + Patch/wireless + Tablet computer => server --- doctor or home ////// Personal medication ’help’! Digital Medicines define Trillion sensorUniverse!

Market potential; 3 Trillion digital doses annually ( 2 Billion patients, 10 illnesses)Goal is a market price based business model!

Is there need for Ubi Diagnostics systems ---- 2Billion patients!

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Vision of integrating solar cells with interior design featuresas energy source in room/office environment

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Freedom of Design

Organic Photovoltaicfor energy harvesting

Organic Light Emitting Diodesin product package

Microfluidic channels

Any shape for light emitting surfaces, solar cells, touch sensors, microfluidic channels etc. with printing

• Arbitrary shapes, any size, decorative design

• Flexible, thin and light-weight

• Various colours, transparency

• Scalability, customising

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Turn any surface to smart User Interface

Capacitive sensors –touchless

Resistive sensors –TransparencyCourtesy FP7 FLEXIBILITY

Force sensors –robustness

Wallpapers, construction elements or furniture canbecome User Interfaces

• Proximity sensing for wide-area user interfaces

• Hidden/visible UI elements for every surface - also conformal

• Thin modular structure for quick installation and configuration

• IoT compatibility – App and cloud connected

Component, System integration, Product parts Battery, Solar cell/Light cell, Antenna, Biosensor, Indicator, Wireless Power, Microfluidics,

Memory, OLED, Optical structures, Transistor, Smart Tags

Roll to Roll processes, manufacturing and measurement equipment Roll to Package - , final assembly, testing, packaging

Materials: ink, substrate, laminating, etc.

Displays, Lighting &Energy sources

Consumer products &Intelligent packages

Sensors&microfluidics

Integration into constructions,Buildings, vehicles, clothes

Home diagnostics WellnessCosmeticsHygiene

Electronics equipmentUser InterfacesWindmill Blades

Business Opportunities in Oulu and in Finland

Electronics &Hybrid systems

Concept, design and manufacturing services

Interactive Point-of-SaleSmart packagingProduct anticounterfeiting

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PrintoCent Innovation Centre

VISION

PrintoCent is printed intelligence and optical measurements world–class innovation centre, whose customers are globally leading companies

commercializes the research results of the Printed Intelligence and Optical Measurement and takes the technologies from

lab-to-fab-to-markets

Regional Goal is to get 1% of the forecast 250 billion €printed electronics market 2030 to Finland and to Oulu =

over 10000 employee

established 2009 - VTT led community to create business• in cooperation with companies – PrintoCent Industrial Members • inline with VTT, University of Oulu, Oulu University of Applied Sciences and Business Oulu –PrintoCent Founding Members• project portfolio 15 M€, company funding 2 M€ - 2009-2012 • showing the maturity of the technology with demos

status 2012 - resources for commercialization & industrialization• over 200 person working years / annum• 15 start-ups established since 2010• five installed manufacturing lines with fulltime operators• multidisciplinary integration of chemistry, biochemistry, optics, electronics, ICT• education in Universities and trainings for Industry

cooperates – excellent networking• COLAE EUFP7 with 17 partners – VTT coordinates – www.colae.eu• PRINSE – seminars 2010 and 2012 for Industry Voice • jointly with other innovation centres globally

based on ongoing research of the founding members (10M€/annum)

PrintoCent profilecommercializes the research results of the Printed Intelligence and Optical Measurement

www.printocent.net

PrintoCent pilot factory concept

Roll to Product

• R2R functionality testing• Component assembly• Injection moulding

R2R Pilot production

• Pilot production for components, products and systems

• Multilayer printing in register• Product testing and characterising

• Ink tuning for R2R process• R2R printing trials• Layer and component prototyping and

testing• R2R process development

Up-scale to R2R

R&D at the research laboratories

• Material research, development and testing

• Printing tests with different techniques• Layer and component characterisation• Application development• Demonstrator manufacturing

R2R

scale

R2R lines

PIC

O-printig

line

RO

KO

-printingline

NIC

O-printing

line

MA

XI-printingline

EVA

-evaporator

RE

EL

LINE

TES

LA-tester

EV

O

EN

KE

LI

SA

MP

O-printing

line

Gravure (frw) X X X X X X

Gravure (rev) X X X

Flexo X X X X

Screen X X X X

Inkjet

Evaporation X X

Die cutting X X X

Hot embossing X X X X

Lamination X X X X X X

Electrical testing X X

Component assembly X X

Injection molding X X

Roll-to-Roll experience and availability:

Testingand finalization

Laboratory facilities

VTT

UO

(University

of Oulu)

OU

AS

(Oulu U

niversityof

Applied

Sciences)

Electrical X X X X

OPV efficency X X X

Luminance X X X

Dimension (2D) X X X

Thickness X X X

Bending X X

Lifetime X X X

Component assembly

X X X

Foil forming X X X

Injection molding X X X X

Testing and finalization facilities:

Way of WorkingHow to co-operate with us?

Signing the project

agreement

Selection of project type

NDA to ensure

confidence

Jointly fundedproject

Customerproject

Project planning

Targets and actions in the

project

Schedule of the porject

Costs of the project

Project at PrintoCentPilot Factory

Regularproject

meetings

Execution and testing

Kickoffmeeting of the

project

Design, research and development

Idea & product

specification

Results jointlyowned

Resultsowned by the

customerProject outcome

Pilot Factory Concept


Operational environment = Pilot Factory

Idea & product

specification

Functional & mechanical

tests

R2R scalefunctional

tests

Onlinemeasure-

ments

150+ researchpersonnel

Manufac-turing control

system

Lab scaleprocesses

R2R scaleprocesses

Hybridprocesses

Sub-contracting

Outcome

Products 1pc-10kpcs

Product specification &

test results

Product structure

Manufac-turing

processes

World-classfacilities

Co-operationnetwork

Manufac-turing linedefinition

Design & Development

Materialknowledge

Product design

knowledge

Component knowledge

Processknowledge

Idea & product

specification

Outcome

Products 1pc-10kpcs

Product specification &

test results

Product structure

Manufac-turing

processes

Manufac-turing linedefinition

We deliver:• Finalized products from single pieces to 10.000 pieces• Processed rolls with registration accuracy and functionality information• Product specification and test results for delivered products• Product structure for made product• Contacts and information of available ink suppliers and inks• Needed process and manufacturing parameters for the product• Definition of needed manufacturing line for product manufacturing• Contacts for manufacturer line suppliers

We need:• Detailed product specification• Structure and layer layouts for the product• Layout files in .dxf-, .dwg-, .gbr-, .pcb- or .cam- format• Undestanding what customer wants to achieve• Inks customers want to use on each layer• Substrates customers want to use for the product

Costs for different outcomes:• POC demonstrator xxxxx >, depending of the complexity of product• One printed layer xxxxx > / 300 meter roll, depending of the materials

and needed process• Product specification for made demonstrators xxxxx €• Manufacturing process for made demonstrators xxxxx €• Definition for manufacturing line xxxxx €


Operational environment

Functional & mechanical

tests

R2R scalefunctional

tests

Onlinemeasure-

ments

100+ researchpersonnel

Manufac-turing control

system

Lab scaleprocesses

R2R scaleprocesses

Hybridprocesses

Sub-contracting

Design & Development

Materialknowledge

Product design

knowledge

Component knowledge

Processknowledge

World-classfacilities

Co-operationnetwork

• Substrates• Inks• Chemicals• Contacts to material

suppliers and non-commercial materials

• Tens of different kindof products made

• Product structureknow-how

• Layout know-how• Electrical design

• Component functionality

• Factors effecting thefunctionality

• Printing techniques• Process equipments• Process parameters• How to improve the

process

• SMT components• Adhesive materials• Bonding techniques• Reliability design

• 4 unique printing lines• R2R evaporator• Equipment develop-

ment• Contacts to tool and

equipment suppliers

• Low ink consumption• Possible to test in

laboratory before R2R• POC demonstrators• Transfer to R2R scale

• Electrical • Dimensional• Thickness• Efficiency

• Electrical• Optical inspection

• Registration accuracy• Printing quality• Layer thickness (-14)

• SME partner networkfor task not possibleor wise to be made at PrintoCent PilotFactory

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Hybrid in-mould intelligence

Integrated functionalities:Sensors & Sensor arrays • User feedback • Processing & Communication •

Power supplies & Storage • Antennas & Wiring

Integration of printed and surface mount discrete electronics components into freeform intelligent products

using roll-to-roll compatible mass manufacturing methods.

Next generation In-Mould-Labelling

from graphic overlays, front panels and labels

owardsmore integrated

Assembled Film Over Moulding

R2R manufacturing cost indication PrintoCent Pilot Factory

Cost example for R2R fabrication at Printocent Pilot Factory.Printing: conductive silver ink (2 layers), UV-curable insulator, resistive carbon ink (4 layers) Substrate: 600m PET roll.

• Materials• Substrate• Silver ink• Insulator ink• Resistive ink

• Tools• Rotary screens (4 layers)

• Facilities & Personnel • Layout Drawing: • Use of MAXI printing line: 1 day, 2 oper.• Testing – Not included• Investment – Not included

TOTAL:Result: 1200 repeat lengths – Reporting: Minimum docs.Repeat length cost: Yield 83%=1000 repeat lengthsUnit cost: Size of 5cm x 5cm (36 pcs/repeat length) 0,xx €/componentTurnover per year: 36.000 pcs/day 100 days/year

Challenges with new PE/PI products

Way of working: `Continuous development of infrastructure, materials, resources`• New equipment in implementation (printing units, measurement, surface treatment,. )• New applications –> burn-in of new printing configurations and testing methods • Materials not yet stabilized -> continuous testing of printing parameters• Personnel risk management -> Specialist/Engineers, researchers! Operators have already

Prime-BackUp -pairs, • Freezing of components – towards Design Kit to be shared with industrial designers

Focus on Printing Quality, Registration Accuracy and Learning/Traceability• Failure mechanism identification, • Adaption of Wise -production management system/ Feeding of data

Stabilizing the quality of standard components

Challenges for process developmentNecessities to be developed

Ability to offer: • Design Kit (st.rules, components, …) to make engineers get interested, • Services for Customer`s demos & products:

• Design&Development&Test Plan, • Manufacturing, • Testing,

• Technology: Lamination/Sealing process, Laser/Vias, Ablation, Double side printing

Ability to collect data of the printing process and analyse it on regular basis• Concurrent product development: design&development&testing – the RECEIPT, • Make the Manufacturing st. tests: In-line ?direct? & Off line, Semiauto & Automatic• Tolerance, yields understanding (normal, special)

Concepts for Manufacturing

COLAE partners

Acronym: COLAEStarting date: 1 Sep 2011Duration: 36 monthsCall: FP7-ICT-2011-7EC budget: EUR 3.75MCoordinator: VTT Technical Research Centre of Finland

OLAE Practical Training Course

www.colae.eu/olae-training

4124/07/2013




Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products /Market

Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll … but looks after complementing

technologies

Industry Cluster pilots 2013-2015Start-Ups, Market trials - towards 100.000 pcs in 24h

Start up companies founded 2010 –MK Fluidics (1) (Biodiagnostics, Oulu)FocalSpec (6) (Optical instrumentation, Oulu)Lumedy (OLED lighting solutions, Oulu) – on holdNanordic (2) (Nanomaterials, Oulu)Iscent (3) (Hot embossed decorative products, Tampere), TactoTek (6) Optical Touch Screens, Oulu – 1.4 M€ VCGlobal Innovation Network (30)( Rapid diagnostics: Production and systems, Oulu) –2 M€ turnoverKeepLoop (3)( Mobile phone microscope, Tampere & Oulu)Spektikor(3), disposable heartbeat monitor, CE acceptance 11/2012Detemex (2), rapid diagnosticsNeficon(4). Development servicesGoodwiller(3), rapid diagnosticsPremisense(4), home monitoringMePromation (1), R2R testing services

Start-UpsStart-Ups

43

Indicates heart beat with flashing LED when dectecting signal from heart

Disposable Heart Beat Indicator

Contact: Kari Kivistö, +358 40 745 3167, [email protected]

GIN Business divisions

44

Cleantech• Water purification• Oil spill prevention

Diagnostics• Manufacturing automation• Point of Care diagnostics

Contact:Matti Koivu+358 400 544 [email protected]

MK Fluidics LtdPrinted diagnostics

companyNarrow web SOM-100 printing machine isdesigned and built for laboratory use forR&D and prototyping of printedelectronics and optics.

Microfluidic prototypes – multiproject ormultidesign processes upto 20cm x 40cm surface area.

Contact: Markku Känsä[email protected]

+358 40 192 0472

Cutting, recombination andwelding of Ni shims to largershims and sleeves for R2Rprocessing and other tools for R2Rprocesses

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Microfluidic power-free display demo:coloured flowing liquid forms the R2R pattern.


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To be start-up: NFC-based interactive packaging concepts


builds a 15 M€ programme 2013 -2015 for its members• projects on Pilot manufacturing, Industrialization and Killer Applications• at least 50% of funding comes from public sources, including EU, regional, etc.• founding members funding – 3 M€ to management, facilities and projects• company funding

• Membership fee - 50 companies - 0.5 M€• Participation to joint specified projects – case by case

offers unique Design, Develop and Pilot Manufacturing Environments• to prototype products and demonstrators for market trials - 100.000 pcs• to reduce commercial and technical risk before fully commercial operation• to develop maturity of industrialization to enable R&D in companies• to be utilized in joint specified projects

targets to Value Chains created by its members• over 50 companies (30.6.2013)• first Member meeting in March 2013 – to start the first projects spring 2013• on-going hunting of killer applications for scale-up • stimulates the start-up creation

PrintoCent 2013 – 2015 programme

PrintoCent ClusterIndustrial and Founding Members

… building value chains …

PrintoCent 2013 – 2015

Cluster and the Three programmes

KillerApplications &

Products3 cases / 100000 pcs,

other cases / tbd

Industrialization

PilotManufacturing

MassMass NicheNiche

Design FlowDesign Flow

MARKETS

TECHNOLOGY

StandardizationStandardization

Multichip runsMultichip runs

PrintoCent 2013-2015

Towards Visions – (almost) Fully printed

`ENERGY BAG`

Organic Photovoltaic - Producing energy to the system

Organic LED & Other - Blinking, Lighting

Rechargeable Battery - Storing the energy

Electronics – Printed control switches, sensors, etc. …. but silicon based communications, processing of data and controlling …

PrintoCent 2013-2015

Summary

Why a research driven cluster ?Multidisciplinary - only few companies could do it aloneComplementary competences need to be collectedPublic sector funding and public-private partnerships

Why born international?Finland has only 1% of resources …Market trials / Products are for global delivery channels – high volumesSubcontractor network is global – inks, substrates, etc.

Why a pilot manufacturing environment for scale-up?

Design & Development & Manufacturing – a close and efficient feedback loopLearning by doing – yield, scrap, machinery, quality control, design rules, New industry creation to Finland

THANK YOU !

Contact:Ilkka Kaisto

+358 40 149 [email protected]

Documents

PrintoCent in Oulu, Finland - Commercializing Printed Intelligence … · 2019-09-01 · Materials, process, components - lntegration to Products/Market Building the Pilot Infrastructure