Reimagining Electronics: How Additive Printing is Changing the Game

In the world of electronics manufacturing, the shift from traditional printed circuit board (PCB) techniques to additive printing processes is more than just a technological evolution—it’s a game-changer. Not only does it simplify production, but it also opens the door to low-cost, flexible, and environmentally friendlier electronics.

So, what makes additive printing so special?

Unlike conventional PCB fabrication, which relies on complex, subtractive methods like photolithography and chemical etching, additive manufacturing builds up the circuit layer by layer. This means fewer processing steps, less material waste, and lower production costs.

Even better, many electronic components use the same materials—such as metals for contacts and interconnects—so multiple components can be printed simultaneously. It’s fast, efficient, and scalable.

Another major advantage? Flexibility.

Literally.

Additive printing techniques, especially when done at low temperatures, are compatible with plastic substrates. This makes it possible to print circuits on flexible materials, paving the way for flexible electronics that can bend, roll, or stretch. With roll-to-roll manufacturing (think of it like printing newspapers), large areas can be covered with electronics at high speed and low cost.

One promising approach for flexible power electronics combines SMT active components (like transistors and chips) with screen-printed passive components (like resistors, capacitors, and inductors). Screen printing, in particular, is ideal for passive parts because it can lay down thick, conductive films quickly—even over large areas—which helps reduce electrical resistance.

A big focus is on replacing bulky SMT inductors with planar spiral inductors that can be printed directly onto flexible substrates. This not only saves space but also makes the entire device more bendable and lightweight—perfect for wearable tech, IoT devices, and more.

And here’s the kicker: efficiency matters. In power electronics, every bit of energy loss in passive components adds up. By minimizing these losses through smart circuit design, printing techniques and materials, we can reduce the size and demands of the energy source powering the device.

The Bottom Line

Additive printing isn’t just an alternative to traditional electronics manufacturing—it’s a better way forward, especially for applications where flexibility, speed, and cost are key. With continued innovation in printed components and solderable printed conductive inks, we’re entering a new era of electronics that are smarter to build, easier to integrate, and ready for the future.