R3D – with adSphere from the roll to the 3D moulded part

Printed and flexible electronics offer numerous benefits for an almost unlimited number of applications, helping you to save huge amounts of raw materials and energy.

Take a control knob input device, for example: Here, the number of parts can be reduced from around 50 standard, individual components to just one single, simple, cheaply produced element. All the functions such as the rotary input, switches and buttons as well as the visual and haptic feedback features are combined in adSphere.Controller.

Benefits of the adSphere R3D process:

• Simple, robust parts
• Cheap to produce
• High integration level
• A single connection for a complete functional unit
• No moving parts or gaps and extremely hygienic

The adSphere R3D process:

Compared with the current situation, the process chain can be reduced to just a few steps: The raw material is a flexible, off-roll film with printed circuits comprising conducting paths, touch elements, junctions and contacts.

The necessary electronic components such as the LEDs and resistors are applied to this surface.

This can already be achieved as a state-of-the-art process with simple means, high precision and high throughput.

What’s new in the adSphere R3D process?

The adSphere R3D process now involves subsequent forming to create three-dimensional geometries – with the high degrees of deformation that we normally see only in the packaging industry (e.g. yoghurt cartons).

Depending on the application, this new moulded part can also be coated, a step that significantly increases robustness – e.g. when used as an input device on ticket machines (weather- and vandal-proof).

The R3D process is possible thanks only to the innovative cera2heat matrix heating technology from watttron, which allows temperature distribution over a surface to be precision-controlled to a very high resolution.

Specific applications for the new input devices in the following areas:

• Medical technology (clean design)
• Automotive (easy, ergonomic, haptic)
• White goods (cheap, design flexibility, robust)
• Consumer electronics (design flexibility, robust)

The adSphere R3D process plant:

adSphere has commissioned this highly compact process plant – the first of its kind anywhere in the world – for forming flexible electronics to create three-dimensional input elements and control panels thanks to its strong network partners in R3D prototype development and process optimisation.