Printed and Flexible Electronics for Automotive Applications 2021-2031: Technologies and Markets

IDTechEx's report 'Printed and Flexible Electronics for Automotive Applications 2021-2031' explores the status and opportunities for printed/flexible electronics in all aspects of automotive design and manufacturing. Drawing on 54 company profiles, the majority based on interviews, it assesses the technological and commercial readiness of emerging printed/flexible electronics technologies across three main aspects of the vehicle. The report includes a 20-year market forecast for the automotive market, delineated by powertrain and autonomy level, and a 10-year market forecast for flexible electronics in automotive applications segmented across 26 forecast categories.

 

 

It is an exciting time for the automotive industry, with multiple technological transitions occurring simultaneously. This of course creates extensive opportunities for many new technologies, including printed/flexible electronics. For example, the ability to make electronics on thin flexible substrates enables weight to be reduced, a key consideration for electric vehicles. Furthermore, the conformality associated with flexible electronics is highly suited to emerging interior design trends with organic curves replacing flat surfaces.

 

The three key technological transitions we identify are:

 

 

 

 

 

 

This technical market research report from IDTechEx outlines the current status of printed/flexible electronics in all aspects of automotive design and manufacturing, along with the future opportunities created by these transitions.

 

The report is divided into three main sections, covering different aspects of the vehicle. Each section is then further segmented into the individual printed/flexible electronics technologies. Along with detailed technical discussion and application examples of the technologies outlined below, the report includes 10-year forecasts for each technology.

 

 

 

Battery monitoring/heating for electric vehicles. Providing the maximum range possible for a given weight and price is a key requirement for electric vehicle manufacturers. This requires batteries to always work as efficiently as possible. However, battery capacity is strongly dependent on temperature. Furthermore, increases in temperature (and pressure) can indicate a malfunction and a possible safety concern. As such, there is an opportunity for printed arrays of temperature sensors to provide local monitoring, and for printed heaters to be integrated within the same functional film.

 

Thermal interface materials for electric vehicles. Although printed electronics are not well-suited to power electronics, they do require printed thermal interface materials for thermal management. Thermal greases are still the norm, but alternatives such as carbon nanotubes and phase change materials are likely to gain traction. As electric vehicles transition to ever higher charging rates, the need for thermal management becomes increasingly important.

 

 

 

Human machine interface (HMI) technologies. A major opportunity for printed/flexible electronics is in human machine interfaces (HMIs) for the interior. Already widely used in seat occupancy sensors, printed pressure sensors are likely to find their way into control panels to provide a wider range of inputs than purely capacitive touch sensors without the expense of mechanical switches. Furthermore, occupancy sensors are likely to evolve into multipoint sensors distributed throughout the seat fabric to monitor passenger comfort.

 

Printed/flexible interior heaters. The existing approach to heating car interiors by blowing hot air around is very inefficient, and highly detrimental to the range of electric vehicles. Printed/flexible electronics to incorporate heaters within touch points is far more efficient - this is approach is likely to extend beyond seats and steering wheels to encompass armrests and center consoles. Furthermore, the conformality of printed electronics enables heaters to be placed much closer to the surface, making heating more efficient and responsive. Transparent conductors take this idea a step further and can be applied directly to the surface of materials such as leather.

 

Emerging manufacturing methodologies for integrating electronics. In-mold electronics is a major trend in automotive manufacturing. By combining the electronics with the thermoformed plastic. It enables integrated systems such as center consoles and overhead control panels to be much lighter, simpler, and easier to manufacture. Indeed, IDTechEx forecast IME to be an approximately $1.3 bn market by 2031. Another emerging manufacturing methodology, albeit a few years further into the future than IME, is printing electronics and dielectric inks directly onto 3D surfaces. This should enable to enable wiring harnesses to be replaced, reducing weight and complexity.

 

Interior displays and lighting. Manufacturers are increasingly aiming to differentiate their vehicles by adding multiple displays. These go beyond the conventional center screen to include digital gauge clusters along with displays for mirrors and passenger entertainment. OLEDs are likely to be increasingly adopted, as the resolution and color gamut meet the expectations consumers transfer from their smartphones. Conformality should also enable a wider range of integration opportunities, such safety improving 'transparent' pillars. Distinctive interior lighting also offers differentiation, with LEDs mounted onto flexible substrates an emerging lightweight and conformal approach.

 

 

 

Hybrid SWIR image sensors. ADAS systems and autonomous vehicles will require as much input information as possible to ensure safety. Imaging in the short-wave infra-red (SWIR) spectral region is especially promising since light scatters less at longer wavelengths, enabling objects to be identified at longer distances in fog or dust. The incumbent technology for SWIR image sensors is prohibitively expensive, so innovative technologies are required. Coating silicon read-out circuits with either organic semiconductors or quantum dots is a highly promising approach.

 

Integrated antennas. Vehicles become more connected every year, necessitating multiple antennas to cover multiple frequency bands. These need to be integrated into plastic body panels, opening opportunities for in-mold electronics and printing onto 3D surfaces. In the future, transparent antennas could also be installed on windows.

 

Exterior lighting. As the level of vehicle autonomy increases, vehicles will need to interact with pedestrians. Low-cost printed/flexible displays are ideally suited to this purpose, as low weight, durability and conformality (including in an accident) are all more important than resolution. Possible approaches include printed LEDs, and mounting LEDs on flexible substrates.

 

Transparent heaters for exterior lighting/sensors/windows. Cameras and LIDAR in autonomous vehicles or ADAS systems will always require a clear view of the road. This means that ensuring that the transparent cover over the sensor is free of mist/frost is essential. Furthermore, thin metal lines could obscure the view of these safety critical components. As such, developing transparent heaters that use transparent conductors such as silver nanowires or CNTs is needed. Over time these technologies are likely to fall in price, enabling them to be applied to windows as well.

 

Printed/flexible photovoltaics. While photovoltaics will never be able to power a car continuously over a long journey, they do enable around 30 km of distance to be added each day. At present electric vehicles with solar panels use silicon photovoltaics, but thin film photovoltaics are a promising alternative due to their lightweight and conformality.

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