In-mold Electronics: The Convergence of Innovative Materials and Manufacturing Techniques

Estimated reading time: 1 minute

Paavo Niskala, a noted expert in in-mold electronics (IME) at TactoTek, recognized the need for an industry-wide standard when one of his automotive OEM clients asked him how to test a prototype TactoTek had developed. That question led to the creation of the first-ever IPC standard of this type, IPC-8401, Guidelines for In-Mold Electronics, to be released later this year.

“When the customer asked me how to test the part, which is a combination of mechanics and electronics, I realized that a standard for IME does not exist, and that sparked the idea that we should do something,” Paavo says. “Later on, the French plastronics network had the same idea. Our proposal and the French proposal led to the formation of the IPC 3D Plastronics Steering Group. Our first face-to-face meeting was in Lyon, France, in April 2022.”

IME technology merges printed electronics, surface mount (SMT) components, and injection molding using mass-production processes, materials, and components. IME parts are structural electronics characterized by their lightweight, seamless integration. This technology appeals to industries such as automotive or aerospace because it reliably enhances the functionality of surfaces in illuminating spaces, such as door panels, center consoles, and front grill emblems. Combining printed electronics, SMT components, and injection molding is an ideal option for mass production due to the simplicity of both processes.

The automotive industry has driven the development of IME because it significantly reduces the cost, weight, waste, and energy required to produce vehicle interior parts. Rather than using a PCB in a plastic molding with features interacting with PCB sensors, IME components are integrated directly into the plastic molding, making the manufacturing process more streamlined, sustainable, and efficient.

“There's a big market pool for IME, especially in the automotive industry, which is looking for sustainable smart structures,” Paavo says of the new technology's appeal. “They want to build lighting on a 3D surface within the vehicle, whether it's an interior or exterior application. For example, automobiles are full of plastic parts. With IME technology, you can make those thin plastic parts smart and build a lighting application you cannot build with conventional electronics.”

To learn more about the standards being developed for in-mold electronics, read the rest of this article in the Summer 2024 issue of IPC Community.