printocent in oulu, finland - commercializing printed intelligence … · 2019-09-01 · materials,...
TRANSCRIPT
Ilkka KaistoPrintoCent, Director
VTT, Printed Functional Solutions
PrintoCent – enabling commercializationof OLAE in Roll-to-Roll manufacturing
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
224/07/2013
Copyright VTT
VTT Center for Printed Intelligence in brief (100 persons)
Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging
Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps
Key customer sectors- Medical and diagnostics- Consumer electronics- Construction and energy- Materials and processes- Consumer packaging
Key customer offering- Contract R&D- Pilot production trials- IPR licensing and sales- Foresight and roadmaps
Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing
Key research areas- Organic devices- Inorganic devices- Printed optoelectronics- Biobased power sources - Biobased indicators- Bio- and microsystems- Integrated solutions- Large-area manufacturing- Pilot manufacturing
Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization 2010-- Pilot Factory 2012
R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration
Program evolution- Project mode late 90’s- R&D program 2006-- Commercialization 2010-- Pilot Factory 2012
R2R infrastructure- Laboratories- R2R printing lines- R2R evaporation unit- R2R laser equipment- R2R hybrid integration
VTT Printed Intelligence 2012 | For external use
The vision is to create easy to use and cost effective products based on sensing, light emitting surfaces, energy foils, optical films and electrical circuits by using printing methods.
VTT GROUP: Turnover 307 M€ (2011) • Personnel 3,187 (31.12.2011)
Read more atwww.vtt.fi
324/07/2013
VTT sites on the globe
SiliconValley,
USA
Saint Petersburg,
Russia
Brussels, Belgium
• •• •
•
Tampere
Oulu
Jyväskylä
Espoo
Lappeenranta
••Turku Rajamäki
• Raahe• Kajaani
Kuopio•
Shanghai, China
Seoul, South Korea
Tokyo, Japan
Finland
424/07/2013
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
Content of Presentation
Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics
Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products/Market
Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll
Industry Cluster pilots 2013-2015Market trials - towards 100.000 pcs in 24h
No more far away!The emphasis of international economy and politics has moved towards north
No more far away!The emphasis of international economy and politics has moved towards north
A long history of creating centre for the world-class research and development
A long history of creating centre for the world-class research and development
The area is a development centre of northern Europe and a hub of northern potential
OULU
Since 2005 the Nokia Cluster: -- 5000 jobs,
mainly on mobile phonesDevelopment & Manufacturing
`Oulu has to find something new`
624/07/2013
Regional Perspective – City of OULU
Free labour force:International, Industry Experienced
Big company oriented – EntrepreneurshipCompetence: Product Design, Development & Manufacturing
Actions taken:Takomo - > 60 companies since 2010
Starttaamo - > 10 M€ vc money Business Kitchen 2012 - > Activation of students
Accelerator - > 90 days boot camp
724/07/2013
Regional Perspective – City of OULUUniversity of Oulu 17.000 students,
Oulu University of Applied Sciences 8000 students
OIA - Oulu Innovation Centers of Excellence
CEE
Centre for Environmentand Energy
CIE
Centre for Internet
Excellence
MAI
Martti Ahtisaari Institute
PrintoCentCenter for
Printed Intelligence
CHT
Centre for Health and Technology
Introduction to printed electronics’New’ revolution in electronics:
1900 1950 2000
Printed TransistorTransistorVacuum tube triode
Radio in every house
Computer on every desk
Electronics everywhere
1906 19
47
2001
924/07/2013
VTT Printed Intelligence
Project modelate 90s - 2005
Strategic research Program
2006 – 2009
CommercializationStage, 2010-Phases
Strong EU-project portfolio created10 10040
Machines
Pico 2003 ROKO 2007 Pilot production MAXI 2012
Major references
Marketing theme
Roll-to-Roll Roll-to-Product Roll-to-Revenue
MetsoAvantone
BASF, Nicanti, UPMOrion Diagnostica
>10 start-up companies established
Productexamples
Orion DiagnosticaCleanCard PRO®
Iscentholographic foil
BASF materials for printed electronics
People
TechnologyMarkets
SystemsProducts
Solutions1
10
100
CHALLENGE:“There is currently a disconnect between the technology supplier and us the end users.”
Pilot factory”-services
R&D & Innovationservices
Killer Applications
Picture copyright: VTT
1224/07/2013
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
Content of Presentation
Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics
Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products/Market
Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll
Industry Cluster pilots 2013-2015Market trials - towards 100.000 pcs in 24h
Introduction to printed electronics
Wetting properties are needed to modify and control in printed electronics!
Inkjet-printer
Precis and accurate deposition on solution based materials is very challenging and it requires deep understanding of wetting phenomena.
Printing methods
Principle of printing methods
Printed electronics can utilize any solution-based material, including organicsemiconductors, inorganic semiconductors, metallic conductors, nanoparticles,nanotubes, etc.
Introduction to printed electronics
Roll-to-roll manufacturing method enables to reduce mass production costs of printed electronics.
Schematic of MEIS structure fabrication in roll-to-roll
Introduction to printed sensors
Printing manufacturing requires multidisiplinary team work:
Printed sensor manufacturing needs number of different materials with completelydifferent properties, but compatible with each other.
• Conductors, semiconductors, dielectrics, functional polymers• There is several commercially available inks.
Custom made ink formulation often is required!
Chemistry Engineering
Physics
Encapsulation
Substrates
Raw materials and inksC
HALLENGES
Processing
1624/07/2013
Solution processable materialsSolution processable materials
Non-vacuum roll-to-roll manufacturing processesNon-vacuum roll-to-roll manufacturing processes
Components, system integration, end products
Printed Intelligence
1724/07/2013
Printed electronics vs. traditional graphical printing
MODIFICATIONSMODIFICATIONS
Separated dotsHigh uniformity requirements
P. Kopola et al., Solar Energy Materials and Solar Cells. Vol. 94 (2010) No: 10, 1673 - 1680 P. Kopola et al., Thin Solid Films. Vol. 517 (2009) No: 19, 5757 - 5762 0 1 2 3 4 5 6 7 8 9 10
0
1
2
3
4
5
Cur
rent
den
sity
[mA
/cm
2 ]Voltage [V]
PEDOT Modified PEDOT
Organic and Large Area Electronics, Printed Intelligence, Printed Electronics
Challenge is how to create products !
Printed passive components 7-segment OLED display Solar energy module Printed memory (WORM)
Hot embossed microfluidistics OLED element Biobattery Printed low-cost indicators
R2R printed Aluminium ink In-mould OLED element
R2R processed OPV foil Opto-fluidic sensor with light source Wide area sensor matrix Active paper
1924/07/2013
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
Content of Presentation
Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics
Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products/Market
Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll
Industry Cluster pilots 2013-2015Market trials - towards 100.000 pcs in 24h
2024/07/2013
Ubiquitous Sensing and DiagnosticsEat a sensor …..
…wireless communication to a reader
Proteus Digital Health Feedback System; tablet/chip(ingestible sensor) + Patch/wireless + Tablet computer => server --- doctor or home ////// Personal medication ’help’! Digital Medicines define Trillion sensorUniverse!
Market potential; 3 Trillion digital doses annually ( 2 Billion patients, 10 illnesses)Goal is a market price based business model!
Is there need for Ubi Diagnostics systems ---- 2Billion patients!
2124/07/2013
Vision of integrating solar cells with interior design featuresas energy source in room/office environment
2224/07/2013
Freedom of Design
Organic Photovoltaicfor energy harvesting
Organic Light Emitting Diodesin product package
Microfluidic channels
Any shape for light emitting surfaces, solar cells, touch sensors, microfluidic channels etc. with printing
• Arbitrary shapes, any size, decorative design
• Flexible, thin and light-weight
• Various colours, transparency
• Scalability, customising
2324/07/2013
Turn any surface to smart User Interface
Capacitive sensors –touchless
Resistive sensors –TransparencyCourtesy FP7 FLEXIBILITY
Force sensors –robustness
Wallpapers, construction elements or furniture canbecome User Interfaces
• Proximity sensing for wide-area user interfaces
• Hidden/visible UI elements for every surface - also conformal
• Thin modular structure for quick installation and configuration
• IoT compatibility – App and cloud connected
Component, System integration, Product parts Battery, Solar cell/Light cell, Antenna, Biosensor, Indicator, Wireless Power, Microfluidics,
Memory, OLED, Optical structures, Transistor, Smart Tags
Roll to Roll processes, manufacturing and measurement equipment Roll to Package - , final assembly, testing, packaging
Materials: ink, substrate, laminating, etc.
Displays, Lighting &Energy sources
Consumer products &Intelligent packages
Sensorsµfluidics
Integration into constructions,Buildings, vehicles, clothes
Home diagnostics WellnessCosmeticsHygiene
Electronics equipmentUser InterfacesWindmill Blades
Business Opportunities in Oulu and in Finland
Electronics &Hybrid systems
Concept, design and manufacturing services
Interactive Point-of-SaleSmart packagingProduct anticounterfeiting
2524/07/2013
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
Content of Presentation
Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics
Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products/Market
Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll
Industry Cluster pilots 2013-2015Market trials - towards 100.000 pcs in 24h
PrintoCent Innovation Centre
VISION
PrintoCent is printed intelligence and optical measurements world–class innovation centre, whose customers are globally leading companies
commercializes the research results of the Printed Intelligence and Optical Measurement and takes the technologies from
lab-to-fab-to-markets
Regional Goal is to get 1% of the forecast 250 billion €printed electronics market 2030 to Finland and to Oulu =
over 10000 employee
established 2009 - VTT led community to create business• in cooperation with companies – PrintoCent Industrial Members • inline with VTT, University of Oulu, Oulu University of Applied Sciences and Business Oulu –PrintoCent Founding Members• project portfolio 15 M€, company funding 2 M€ - 2009-2012 • showing the maturity of the technology with demos
status 2012 - resources for commercialization & industrialization• over 200 person working years / annum• 15 start-ups established since 2010• five installed manufacturing lines with fulltime operators• multidisciplinary integration of chemistry, biochemistry, optics, electronics, ICT• education in Universities and trainings for Industry
cooperates – excellent networking• COLAE EUFP7 with 17 partners – VTT coordinates – www.colae.eu• PRINSE – seminars 2010 and 2012 for Industry Voice • jointly with other innovation centres globally
based on ongoing research of the founding members (10M€/annum)
PrintoCent profilecommercializes the research results of the Printed Intelligence and Optical Measurement
www.printocent.net
PrintoCent pilot factory concept
Roll to Product
• R2R functionality testing• Component assembly• Injection moulding
R2R Pilot production
• Pilot production for components, products and systems
• Multilayer printing in register• Product testing and characterising
• Ink tuning for R2R process• R2R printing trials• Layer and component prototyping and
testing• R2R process development
Up-scale to R2R
R&D at the research laboratories
• Material research, development and testing
• Printing tests with different techniques• Layer and component characterisation• Application development• Demonstrator manufacturing
R2R
scale
R2R lines
PIC
O-printig
line
RO
KO
-printingline
NIC
O-printing
line
MA
XI-printingline
EVA
-evaporator
RE
EL
LINE
TES
LA-tester
EV
O
EN
KE
LI
SA
MP
O-printing
line
Gravure (frw) X X X X X X
Gravure (rev) X X X
Flexo X X X X
Screen X X X X
Inkjet
Evaporation X X
Die cutting X X X
Hot embossing X X X X
Lamination X X X X X X
Electrical testing X X
Component assembly X X
Injection molding X X
Roll-to-Roll experience and availability:
Testingand finalization
Laboratory facilities
VTT
UO
(University
of Oulu)
OU
AS
(Oulu U
niversityof
Applied
Sciences)
Electrical X X X X
OPV efficency X X X
Luminance X X X
Dimension (2D) X X X
Thickness X X X
Bending X X
Lifetime X X X
Component assembly
X X X
Foil forming X X X
Injection molding X X X X
Testing and finalization facilities:
Way of WorkingHow to co-operate with us?
Signing the project
agreement
Selection of project type
NDA to ensure
confidence
Jointly fundedproject
Customerproject
Project planning
Targets and actions in the
project
Schedule of the porject
Costs of the project
Project at PrintoCentPilot Factory
Regularproject
meetings
Execution and testing
Kickoffmeeting of the
project
Design, research and development
Idea & product
specification
Results jointlyowned
Resultsowned by the
customerProject outcome
Pilot Factory Concept
Execution and testing
Operational environment = Pilot Factory
Idea & product
specification
Functional & mechanical
tests
R2R scalefunctional
tests
Onlinemeasure-
ments
150+ researchpersonnel
Manufac-turing control
system
Lab scaleprocesses
R2R scaleprocesses
Hybridprocesses
Sub-contracting
Outcome
Products 1pc-10kpcs
Product specification &
test results
Product structure
Manufac-turing
processes
World-classfacilities
Co-operationnetwork
Manufac-turing linedefinition
Design & Development
Materialknowledge
Product design
knowledge
Component knowledge
Processknowledge
Idea & product
specification
Outcome
Products 1pc-10kpcs
Product specification &
test results
Product structure
Manufac-turing
processes
Manufac-turing linedefinition
We deliver:• Finalized products from single pieces to 10.000 pieces• Processed rolls with registration accuracy and functionality information• Product specification and test results for delivered products• Product structure for made product• Contacts and information of available ink suppliers and inks• Needed process and manufacturing parameters for the product• Definition of needed manufacturing line for product manufacturing• Contacts for manufacturer line suppliers
We need:• Detailed product specification• Structure and layer layouts for the product• Layout files in .dxf-, .dwg-, .gbr-, .pcb- or .cam- format• Undestanding what customer wants to achieve• Inks customers want to use on each layer• Substrates customers want to use for the product
Costs for different outcomes:• POC demonstrator xxxxx >, depending of the complexity of product• One printed layer xxxxx > / 300 meter roll, depending of the materials
and needed process• Product specification for made demonstrators xxxxx €• Manufacturing process for made demonstrators xxxxx €• Definition for manufacturing line xxxxx €
Execution and testing
Operational environment
Functional & mechanical
tests
R2R scalefunctional
tests
Onlinemeasure-
ments
100+ researchpersonnel
Manufac-turing control
system
Lab scaleprocesses
R2R scaleprocesses
Hybridprocesses
Sub-contracting
Design & Development
Materialknowledge
Product design
knowledge
Component knowledge
Processknowledge
World-classfacilities
Co-operationnetwork
• Substrates• Inks• Chemicals• Contacts to material
suppliers and non-commercial materials
• Tens of different kindof products made
• Product structureknow-how
• Layout know-how• Electrical design
• Component functionality
• Factors effecting thefunctionality
• Printing techniques• Process equipments• Process parameters• How to improve the
process
• SMT components• Adhesive materials• Bonding techniques• Reliability design
• 4 unique printing lines• R2R evaporator• Equipment develop-
ment• Contacts to tool and
equipment suppliers
• Low ink consumption• Possible to test in
laboratory before R2R• POC demonstrators• Transfer to R2R scale
• Electrical • Dimensional• Thickness• Efficiency
• Electrical• Optical inspection
• Registration accuracy• Printing quality• Layer thickness (-14)
• SME partner networkfor task not possibleor wise to be made at PrintoCent PilotFactory
3524/07/2013
Hybrid in-mould intelligence
Integrated functionalities:Sensors & Sensor arrays • User feedback • Processing & Communication •
Power supplies & Storage • Antennas & Wiring
Integration of printed and surface mount discrete electronics components into freeform intelligent products
using roll-to-roll compatible mass manufacturing methods.
Next generation In-Mould-Labelling
from graphic overlays, front panels and labels
owardsmore integrated
Assembled Film Over Moulding
R2R manufacturing cost indication PrintoCent Pilot Factory
Cost example for R2R fabrication at Printocent Pilot Factory.Printing: conductive silver ink (2 layers), UV-curable insulator, resistive carbon ink (4 layers) Substrate: 600m PET roll.
• Materials• Substrate• Silver ink• Insulator ink• Resistive ink
• Tools• Rotary screens (4 layers)
• Facilities & Personnel • Layout Drawing: • Use of MAXI printing line: 1 day, 2 oper.• Testing – Not included• Investment – Not included
TOTAL:Result: 1200 repeat lengths – Reporting: Minimum docs.Repeat length cost: Yield 83%=1000 repeat lengthsUnit cost: Size of 5cm x 5cm (36 pcs/repeat length) 0,xx €/componentTurnover per year: 36.000 pcs/day 100 days/year
Challenges with new PE/PI products
Way of working: `Continuous development of infrastructure, materials, resources`• New equipment in implementation (printing units, measurement, surface treatment,. )• New applications –> burn-in of new printing configurations and testing methods • Materials not yet stabilized -> continuous testing of printing parameters• Personnel risk management -> Specialist/Engineers, researchers! Operators have already
Prime-BackUp -pairs, • Freezing of components – towards Design Kit to be shared with industrial designers
Focus on Printing Quality, Registration Accuracy and Learning/Traceability• Failure mechanism identification, • Adaption of Wise -production management system/ Feeding of data
Stabilizing the quality of standard components
Challenges for process developmentNecessities to be developed
Ability to offer: • Design Kit (st.rules, components, …) to make engineers get interested, • Services for Customer`s demos & products:
• Design&Development&Test Plan, • Manufacturing, • Testing,
• Technology: Lamination/Sealing process, Laser/Vias, Ablation, Double side printing
Ability to collect data of the printing process and analyse it on regular basis• Concurrent product development: design&development&testing – the RECEIPT, • Make the Manufacturing st. tests: In-line ?direct? & Off line, Semiauto & Automatic• Tolerance, yields understanding (normal, special)
Concepts for Manufacturing
COLAE partners
Acronym: COLAEStarting date: 1 Sep 2011Duration: 36 monthsCall: FP7-ICT-2011-7EC budget: EUR 3.75MCoordinator: VTT Technical Research Centre of Finland
OLAE Practical Training Course
www.colae.eu/olae-training
4124/07/2013
PrintoCent in Oulu, Finland - Commercializing Printed Intelligence
Content of Presentation
Perspectives – From Regional City of OULU to GlobalIntroduction to industrialization of Printed Electronics
Technology Push …………. Business OpportunityMaterials, process, components - lntegration to Products /Market
Building the Pilot Infrastructure 2008-2012Versatile environment – Roll-to-Roll … but looks after complementing
technologies
Industry Cluster pilots 2013-2015Start-Ups, Market trials - towards 100.000 pcs in 24h
Start up companies founded 2010 –MK Fluidics (1) (Biodiagnostics, Oulu)FocalSpec (6) (Optical instrumentation, Oulu)Lumedy (OLED lighting solutions, Oulu) – on holdNanordic (2) (Nanomaterials, Oulu)Iscent (3) (Hot embossed decorative products, Tampere), TactoTek (6) Optical Touch Screens, Oulu – 1.4 M€ VCGlobal Innovation Network (30)( Rapid diagnostics: Production and systems, Oulu) –2 M€ turnoverKeepLoop (3)( Mobile phone microscope, Tampere & Oulu)Spektikor(3), disposable heartbeat monitor, CE acceptance 11/2012Detemex (2), rapid diagnosticsNeficon(4). Development servicesGoodwiller(3), rapid diagnosticsPremisense(4), home monitoringMePromation (1), R2R testing services
Start-UpsStart-Ups
43
Indicates heart beat with flashing LED when dectecting signal from heart
Disposable Heart Beat Indicator
Contact: Kari Kivistö, +358 40 745 3167, [email protected]
GIN Business divisions
44
Cleantech• Water purification• Oil spill prevention
Diagnostics• Manufacturing automation• Point of Care diagnostics
Contact:Matti Koivu+358 400 544 [email protected]
MK Fluidics LtdPrinted diagnostics
companyNarrow web SOM-100 printing machine isdesigned and built for laboratory use forR&D and prototyping of printedelectronics and optics.
Microfluidic prototypes – multiproject ormultidesign processes upto 20cm x 40cm surface area.
Contact: Markku Känsä[email protected]
+358 40 192 0472
Cutting, recombination andwelding of Ni shims to largershims and sleeves for R2Rprocessing and other tools for R2Rprocesses
24/07/2013 46
Microfluidic power-free display demo:coloured flowing liquid forms the R2R pattern.
VTT Printed Intelligence 2012 | For external use
24/07/2013 47
To be start-up: NFC-based interactive packaging concepts
VTT Printed Intelligence 2012 | For external use
builds a 15 M€ programme 2013 -2015 for its members• projects on Pilot manufacturing, Industrialization and Killer Applications• at least 50% of funding comes from public sources, including EU, regional, etc.• founding members funding – 3 M€ to management, facilities and projects• company funding
• Membership fee - 50 companies - 0.5 M€• Participation to joint specified projects – case by case
offers unique Design, Develop and Pilot Manufacturing Environments• to prototype products and demonstrators for market trials - 100.000 pcs• to reduce commercial and technical risk before fully commercial operation• to develop maturity of industrialization to enable R&D in companies• to be utilized in joint specified projects
targets to Value Chains created by its members• over 50 companies (30.6.2013)• first Member meeting in March 2013 – to start the first projects spring 2013• on-going hunting of killer applications for scale-up • stimulates the start-up creation
PrintoCent 2013 – 2015 programme
PrintoCent ClusterIndustrial and Founding Members
… building value chains …
PrintoCent 2013 – 2015
Cluster and the Three programmes
KillerApplications &
Products3 cases / 100000 pcs,
other cases / tbd
Industrialization
PilotManufacturing
MassMass NicheNiche
Design FlowDesign Flow
MARKETS
TECHNOLOGY
StandardizationStandardization
Multichip runsMultichip runs
PrintoCent 2013-2015
Towards Visions – (almost) Fully printed
`ENERGY BAG`
Organic Photovoltaic - Producing energy to the system
Organic LED & Other - Blinking, Lighting
Rechargeable Battery - Storing the energy
Electronics – Printed control switches, sensors, etc. …. but silicon based communications, processing of data and controlling …
PrintoCent 2013-2015
Summary
Why a research driven cluster ?Multidisciplinary - only few companies could do it aloneComplementary competences need to be collectedPublic sector funding and public-private partnerships
Why born international?Finland has only 1% of resources …Market trials / Products are for global delivery channels – high volumesSubcontractor network is global – inks, substrates, etc.
Why a pilot manufacturing environment for scale-up?
Design & Development & Manufacturing – a close and efficient feedback loopLearning by doing – yield, scrap, machinery, quality control, design rules, New industry creation to Finland