It’s the 21st century and by now most of the population depends on some or the other kind of electronic gadget for their day-to-day activities. All kinds of electronic devices surround the world and it would be fair to say that life would be difficult without those amenities. 

1. Evolving Electronics

To express in words, equipment that requires the flow of electrical energy to process, store and transmit data is said to be an electronic device. These circuits are built with semiconductor materials such as silicon and are rudimentary to advanced technology. 

Electronics have had a prominent impact on several societal attributes, from communication to healthcare and entertainment. With the invention of radios, televisions, smartphones, and the internet, the emergence of electronics has reshaped communication. These devices have connected people worldwide, allowing instant information exchange and revolutionizing how people interact.

In the entertainment domain, electronics have opened doors to a series of innovations, including high-definition televisions, digital sound systems, gaming consoles, and most recently virtual reality platforms, offering a captivating experience and incomparable access to multimedia essence.

Entertainment aside, these devices also have a significant role to play in healthcare and medical research. Electronics have enabled advanced imaging systems, wearable health monitors, and life-saving devices such as pacemakers resulting in improvements in patient care and outcomes.

Additionally, electronics are contributing to the automotive industry, fueling modern safety features like GPS navigation systems, and electric vehicles, leading towards a sustainable future.

In the field of computing, devices such as laptops and tablets, have been developed with the advent of electronics. These technologies have accelerated research and productivity. 

As electronics keep evolving, they ensure progress in artificial intelligence, space exploration, robotics, and renewable energy, modelling the future of technology. However, it is also essential to ensure that electronics contribute positively to the world and address issues such as e-waste management and cybersecurity. 

2. Mankind and Electronics

The relationship between people and electronics is progressing and proximate. Electronics play a significant role in today’s world and have become essential to one’s daily life. 

Here is a list of how electronics have a significant impact on an individual’s life:

Electronics, particularly smartphones, and computers have made it easier for people to connect with other people across the globe, using several platforms like social media, e-mail, video-conferencing, etc., regardless of geographical differences. 

Electronics provide a wide variety of options for entertainment, such as televisions, gaming consoles, audio systems, and streaming services, allowing people to relax and have fun during their leisure time.

In the workplace, computers, tablets, and smartphones, have reshaped how people work and elevated overall work productivity, as they have enabled faster data processing and a streamlined workflow.

Education has been transformed with the help of electronics, by providing online learning platforms, digital textbooks, and educational apps. The affluence of knowledge and resources from all over the world, are available to the youth, enhancing the learning experience.

There have been significant advancements in the healthcare industry, with the rise of electronics. Devices such as pacemakers, fitness trackers, and medical imaging apparatus have improved the diagnosis, treatment, and monitoring of several medical conditions.

The Internet of Things, popularly known as IoT, has been able to connect daily objects and gadgets to the Internet, enabling data collection, automation, and remote control. Wearable devices are prime examples of how electronics have become an integral part of one’s life. 

The demand for electronics goes hand in hand with the fast-paced development of technologies. Overall, the relationship between humans and electronics is multi-dimensional and complex, having impacts on several aspects of life, ranging from entertainment to communication. With advancements in electronics, this association will also continue evolving. 

3. What are Flexible Electronics?

Also known as bendable electronics, flexible electronics are a class of electronic circuits and devices designed to be highly durable, flexible, and malleable. These devices are made to withstand twisting or conforming to various surfaces and shapes.

In contrast to typical rigid electronics, which are generally based on silicon and other friable materials, flexible electronics incorporate flexible materials such as metal foils or plastic, allowing them to resist mechanical stress and distortion. 

The advancement of bendable electronics has opened up innovative opportunities for approaches in several industries. One of the significant advantages is its ability to create portable, lightweight, and wearable gadgets that flawlessly incorporate into daily activities, such as flexible displays, e-textiles, and foldable smartphones. 

The manufacturing process of these electronics usually involves ingenious methods of printing, such as inkjet printing, screen printing, or roll-to-roll printing, which enable the economical and extensible production of electronic components on flexible substrates.

These electronics find utilization in areas like medical care, where they can be combined into wearable health monitors. They are also applicable in the automotive industry,  as they enable flexible sensors for improved safety and ease.

Additionally, flexible electronics play a part in the Internet of Things (IoT), where they provide a means to incorporate electronics into everyday items and surfaces.

With continuous research and development, flexible electronics or bendable electronics are foreseeable to bring about further upgrades, and the expansion of lightweight, versatile, and adaptive programming that has the prospect of transforming various aspects of people’s lives.

Although a few challenges in terms of material durability, performance, and compatibility with conventional manufacturing processes continue to exist, researchers are actively aiming to unleash the full potential of flexible electronics. 

4. History of Flexible Electronics

The history of bendable electronics can be traced back to the mid-20th century when researchers began exploring the whole idea of electronic devices that could be bent and twisted. Here is an overview of the milestones achieved so far in this area:

It was during the 1940s and 1950s when the concept of flexible electronics emerged, with researchers experimenting with flexible and conductive materials. However, considerable progress was hindered due to the unavailability of materials and technological limitations, during this period. 

The elevation of conductive inks and polyimide films supported the development of bendable circuits, in the 1970s. These circuits utilized thin and flexible substrates, capable of some level of twisting and folding. 

In the 1980s and 1990s, the world saw the rise of organic light-emitting diode (OLED) displays. OLEDs utilize flexible organic implements, allowing the production of flexible displays with finer picture attributes and energy efficiency.

The initial 2000s ascertained significant advancements in flexible electronics due to the development of flexible materials like polymer blends and nanomaterials. These materials improved the durability, malleability, stretchability, and electrical performance of flexible gadgets.

During the 2010s, there was an upsurge in wearable electronics, driven by flexible electronics technology. Wearable devices like fitness trackers and smartwatches, gained acclaim, showcasing the perspective of flexible electronics in customer applications.

In the present time, foldable smartphones have begun to further encourage the confines of flexible electronics. Manufacturers have started forming devices with displays that can be folded or bent, offering new form factors and user experiences.

5. Manufacturing 

Fabricating flexible electronics engages specialized approaches to create electronic components and circuits on flexible substrates. These processes vary from conventional rigid electronics manufacturing due to the requirement to fit the deformable nature of the materials. Here’s an outline of the key steps involved in manufacturing flexible electronics:

Selecting a suitable flexible substrate, such as plastic films like polyimide or PET or metal foils like copper or aluminum, is the first step. The choice of substrate is based on the application, flexibility requirements, and desired properties. This is also termed substrate selection.

The next step is the Deposition Technique. Different deposition processes such as physical vapor deposition (PVD) and chemical vapor deposition (CVD), are used to deposit conductive and semiconductor materials onto the substrate. Printing techniques like inkjet printing are employed for economical manufacturing.

Further, Photolithography or laser ablation methods are used to form patterns and circuits on the substrate. This step defines the layout of the electronic components, such as transistors, interconnects, and sensors.

Using pick-and-place machinery, or roll-to-roll assembly techniques, transistors, diodes, and resistors are fitted on the substrate. To protect those components from various factors, bendable electronics are encased with protective layers such as polymer coatings or encapsulation films.

To check for the functionality and reliability of the devices, they undergo rigorous testing and quality control measures. Special attention is given to the assessment of the mechanical durability of the gadgets under stretching and folding conditions. 

For large-scale manufacturing, roll-to-roll processes are employed, where flexible substrates are continuously processed, allowing mass production at lower costs. 

6. Costs of Flexible Electronics 

The cost of flexible electronics depends upon multiple factors, including the selection of materials, manufacturing processes, complexity of the device, and volume of production. As the technology becomes more widely acquired, the costs have been moderately decreasing, making flexible electronics more commercially feasible. Here are some accounts that impact the cost:

The selection of substrates, conductive inks, and other materials considerably affects the overall cost. High-quality, specialized materials designed for flexibility and durability can be expensive, but improvements in material development and larger-scale production have helped lower costs over the years.

Flexible electronics frequently require specific manufacturing methods, such as roll-to-roll printing or vacuum deposition. These processes may have higher apparatus costs but may provide cost advantages for mass production.

The intricacy of the bendable or foldable electronic device, including the number of components, circuitry, and integration of performances, can influence the gross manufacturing cost. Complex designs may require more precise fabricating techniques, resulting in higher costs.

In the initial days of research and development costs can be considerable. Although costs can be significant as new technologies and materials are discovered, however, as the technology evolves and becomes standardized, these costs tend to decline.

Economies of scale play a vital role in the cost of these electronics. The greater the production volumes lower the costs per unit, making large-scale production more cost-effective. Applications may determine the cost, like higher demand for the application allows for more competitive pricing, whereas custom applications might have higher costs due to finite production volume.

The costs associated with combining electronic components, assembly, testing, and quality control also play a role in the overall cost of flexible electronics.

As the field of flexible electronics is explored, continued development, advancements in materials and manufacturing methods, and expanding market demand are expected to further lower costs, making flexible electronics easily accessible for a wide range of applications and sectors.

7. Types of Flex Circuits: An Overview

Flexible circuits or flex circuits come in several configurations, depending on the application and materials used. As the name suggests, these circuits are flexible and can be bent, reshaped, or twisted as per the requirements. Here are some different types of flex circuits:

7.1. Single-Sided Flexible Circuits

These are the simplest form of flex circuits, made up of a single conductive layer on a flexible substrate. They are generally suitable for elemental applications where a limited number of components need to be integrated.

7.2. Double-Sided Flexible Circuits

These circuits have conductive layers on both sides of the flexible substrate, enabling more intricate interconnections and component placement. They provide higher routing density and are mostly used in more refined electronics.

7.3. Multilayer Flexible Circuits

These circuits consist of multiple conductive layers separated by insulating layers, enabling complex linkages and increased performance. They can aid complex electronic designs with multiple components and high-density interconnects.

7.4. Rigid-Flex Circuits

Rigid-flex circuits combine flexible substrates with the addition of rigid sections, providing the benefits of both materials. They are used in applications where a blend of flexibility and structural stability is necessary.

7.5. Sculptured Flex Circuits

In sculptured flex circuits, the copper conductors are selectively thinned to create flexible areas with differing thicknesses. This enables bending and flexibility in distinct regions while maintaining rigidity in others.

7.6. Single-Layer Double Access Flex Circuits

These circuits have conductive layers on one side of the flexible substrate and are plated through holes that permit access to the other side. They are required when connections need to be made between the top and bottom layers of a single-sided flexible circuit.

Each type of flexible circuit offers specialized benefits and is chosen considering the application’s requirements, space constraints, and performance needs. These circuits are largely used in industries like consumer electronics, automotive, aerospace, medical devices, and mostly, where space-saving and flexible designs are critical.

8. Advantages and Disadvantages

The most important advantage of flexible electronics is that they can be conformed into any shape based on the requirement. This characteristic allows innovative designs, making them suitable for unusual form factors and space-restrained applications.

Flexible electronics are lightweight and thin, lowering the overall weight and size, making them portable, and improving user comfort and movement. They are durable, malleable, and flexible, making them resistant to mechanical stress, as compared to rigid electronics.

These electronics incorporate efficient use of space and hence reduce overall costs. They can be customized to suit multiple applications and can be fabricated to integrate different components, sensors, and functionalities, making them versatile.

Talking about disadvantages, in a few cases, flexible materials may have lower conductivity as compared to their rigid counterparts. The manufacturing process of these electronics is generally intricate and specialized and can lead to higher production costs.

The flexibility of the material may restrain certain design modifications, affecting the layout of components, and leading to an impact on the overall complexity and density. Some components may not be compatible with flexible substrates, and their specialized versions may be required.

Flexible electrons can be more sensitive to environmental factors such as moisture and variation in temperature, making proper protection necessary.

Despite these challenges, researchers continue to explore this sector and aim to improve the performance, reliability, and cost-effectiveness of flexible electronics. With time they are expected to offer innovative possibilities and have a larger demand in multiple industries. 

9. Applications

Flexible electronics find applications in multiple industries. These include wearable gadgets such as smartwatches, e-textiles, fitness trackers, etc. Foldable smartphones, and rollable OLED displays, are examples of how flexible electronics are advancing the display industry.

Flexible electronics are used in medical applications, including smart medical patches and implantable medical devices, allowing improved patient comfort and better integration with the human body.

In the automotive industry, flexible electronics are applied in curved displays, flexible touchscreens, and flexible lighting solutions. They also have applications in robotics and prosthetics, aerospace, defence, energy harvesting, and consumer electronics.

Last Updated on September 15, 2023 by Apeksha Soni