Printed sensors—a technology of the future
Printable, flexible sensors are an innovative technology that is interesting for many industries due to their flexibility, cost efficiency and versatility. These innovative, flexible sensors are no longer produced in complicated manufacturing processes but are now printed on flexible films just like ink. This opens up fascinating possibilities and holds enormous potential for a wide range of industries. The possible applications for printed sensors are virtually unlimited. Printed sensors are already revolutionizing a wide range of industries, such as medical technology, the automotive industry, environmental monitoring and industrial automation.
Printed sensors: driving global trends and innovations
Printed, flexible sensors are an important technology that can actively support major global trends such as digitization, demographic change and the transition to more sustainable mobility.
Printed sensors are an area of printed electronics that offer various benefits compared to conventional semiconductor sensors. They are cost-effective, since their production requires less material and energy, and they are scalable. In contrast to conventional conductive paths, they are also flexible, since they are light, thin and pliable, which makes them ideal for applications that would not be feasible with rigid sensors. They are also versatile, since different materials and printing techniques can be used to adapt their properties to suit specific requirements.
Research and development in the field of printed sensors is in full swing worldwide. Universities, research institutes, such as the Fraunhofer Institutes, and various companies are investing heavily in advancing the technology and finding new applications. The market for printed, flexible sensors is growing fast. According to various market research reports, such as Fortune Business Insights, it is expected to reach several billion dollars in the next few years. Growth is being driven primarily by applications in health technology, the automotive industry, environmental protection, wearables and industrial automation.
Design and manufacture of printed sensors
As opposed to conventional sensors, which consist of individual components, printed sensors are applied in thin layers to flexible substrates such as films, paper, textiles or glass. In the first step, the sensor is designed to take into account the desired function, sensitivity and selectivity.
The choice of materials is crucial for the performance of the printed sensor. Conductive inks consisting of metals, nanoparticles or conductive polymers are used for the sensor elements. Dielectric materials are used for insulation, while substrates provide mechanical support.
Various printing processes are used for the electrical circuits. These processes offer different benefits in terms of resolution, speed and material compatibility. The choice of printing process depends on the size, complexity and desired resolution of the sensor. After printing, the sensor can be functionalized with additional coatings or treatments to improve its properties.
Printing processes used to manufacture sensors
Screen printing:
A stencil (screen printing form) is used to print the conductive ink through a fine-mesh screen onto the substrate. Advantages: Suitable for thicker, more robust layers and large applications.
Inkjet printing:
Tiny drops of conductive ink are sprayed precisely onto the substrate. Advantages: High resolution and flexibility, ideal for fine structures and customized designs.
Flexographic printing:
A flexible printing plate transfers the ink to the substrate. Advantages: Fast and efficient for large volumes, suitable for continuous production processes.
Gravure printing:
An engraved roll applies the ink to the substrate. Advantages: High resolution and detail, ideal for fine and precise printing.
Roll-to-roll printing:
Continuous production process in which flexible materials, such as films or thin metal strips, are unwound from a roll, printed and wound onto another roll. Advantages: Efficient for mass production, suitable for long and flexible substrates.
3D printing:
Structures made of conductive materials are developed layer by layer. Advantages: Enables the production of complex three-dimensional structures.
What are the different types of sensors?
Printed sensors come in a variety of types designed for different applications and measurements. Here are some of the most common types:
- Pressure sensors: Monitoring pressure in tires, engines and other industrial applications; portable monitoring devices, such as for measuring blood pressure
- Temperature sensors: Measuring temperatures in vehicles, food, packaging and buildings (smart homes), monitoring body temperature in wearables
- Biosensors: Detection of biomolecules such as glucose, DNA and proteins for medical and diagnostic applications
- Chemical sensors: Detection of gases, vapors and other pollutants in the vehicle interior, in the environment and in industrial processes
- Humidity sensors: Monitoring humidity in buildings, air conditioning systems and other environments
- Capacitive sensors: Measurement of changes in capacitance, often used for touch detection in touchscreens and touch-sensitive control elements.
Areas of application for printed sensors
Printed, flexible sensors already play an important role. An increasing number of user industries—such as automotive, renewable energies and medicine—use them as a key technology in order to make their products more environmentally friendly and more sustainable. The benefits, such as cost efficiency, flexibility, versatility and miniaturization, open up many possibilities for innovative products and applications.
The following applications are examples of the potential of printed, flexible sensors:
Medical technology:
Monitoring of vital signs such as heart rate, blood pressure and body temperature. Printed sensors also enable the use of wearable medical devices that continuously collect data, such as smart patches that are stuck to the skin to collect and analyze physiological data.
Automotive industry:
Monitoring of temperature, pressure, humidity and air quality in the vehicle interior as well as seat occupancy and other important parameters in vehicles.
Environmental monitoring:
Detection of pollutants in air, water and soil.
Wearables:
Integration in clothing for monitoring body functions, fitness tracking and health monitoring. Printed sensors also enable the development of intelligent textiles.
Industry:
Monitoring of machines and production processes. Printed sensors help increase efficiency and reduce downtime.
Consumer goods:
Used in intelligent packaging to monitor the freshness of food or the condition of sensitive products. They are also used in household appliances and consumer electronics.
Smart homes:
Integration into household appliances to monitor and control environmental conditions such as temperature and humidity. They contribute to the creation of intelligent and networked living environments.
Logistics and transportation:
Monitoring conditions during transportation of sensitive goods, such as temperature and humidity, to ensure that products arrive undamaged.
Battery management:
Monitoring of charging and discharging cycles as well as the temperature in battery systems.
What are the advantages of printed sensors?
Cost-effective: The manufacturing processes are scalable and require less material and energy, which, in turn, reduces costs. This makes these sensors particularly interesting for mass products and applications in price-sensitive areas.
Flexibility: The components are light, thin and flexible, making them suitable for a variety of applications that cannot be realized with rigid PCBs. They can be applied to films, paper, textiles and even curved surfaces.
Versatility: Different materials and printing processes allow the properties of the PE components to be adapted to specific requirements. For example, conductive, resistive, optical or sensory properties can be realized.
Miniaturization: Thanks to printing technology, printed sensors can be produced in very small dimensions, which enables new applications in areas such as microfluidics or biomedicine.
Sustainability: The sensors can be made from recycled materials, and the energy-efficient production and long service life of the components also contribute to sustainability.
Rapid prototype development: Printing technology enables prototypes to be produced quickly and cost-effectively, which shortens the development time for new products.
Extended functionalities: Printed sensors allow the integration of electronics into objects and materials that could previously not be electronically functionalized. This opens up a wide range of possibilities for innovative products and applications.
Experience printed sensors live at LOPEC
Discover everything you want to know about flexible, printed sensors—from design and principles to areas of use and applications at LOPEC 2025 from February 26-27, 2025 in Munich. LOPEC is the world’s leading exhibition and conference for printed electronics. The combination of trade fair and conference ideally reflects the complexity and dynamics of this young industry and offers a first-rate meeting place for manufacturers, consumer industries and research institutes.
The parallel LOPEC Conference is the most important communication platform in the rapidly growing market for flexible and printed electronics and is a leading international event. LOPEC brings together key players from industry and research and showcases interesting applications that improve many aspects of everyday life and enable technological advances.
Frequently asked questions about printed sensors
By combining advanced materials and printing techniques, printed sensors offer new possibilities for monitoring, control and interaction in a variety of areas. Here are some frequently asked questions (FAQs) about printed flexible sensors:
Printed sensors are an area of printed electronics in which electronic components are manufactured using printing techniques. They consist of conductive inks or pastes that are printed on flexible materials such as plastic, paper or film. These sensors measure physical, chemical or biological parameters by responding to changes in the environment with electrical signals.
Printed sensors are less expensive to produce than conventional semiconductors, as lower-cost materials and printing techniques are used. These sensors can be printed on flexible substrates such as plastic or paper, making them ideal for applications that require flexibility, such as wearables and portable electronics. They are lighter than conventional sensors, which makes them interesting for portable devices and applications in the aerospace industry, for example.
The printing techniques used allow the production of large numbers of sensors quickly and cost-effectively, and they can be manufactured in different shapes and sizes, which allows a high degree of adaptability to specific applications. They can also be easily integrated into existing electronic systems and devices. They can be manufactured using environmentally friendly materials and processes, which contributes to sustainability.
The market for printed flexible sensors is growing rapidly and has enormous potential. According to various market research reports, this market is expected to reach a volume of several billion dollars in the next few years. The market is driven by increasing demand from various industries, such as medical technology, automotive, environmental monitoring, wearables and industrial automation.
Printed sensors are manufactured using various printing processes that enable conductive materials to be applied to flexible substrates.
The materials used for printed sensors include conductive inks, which are often made of silver, copper or carbon nanotubes. Flexible materials such as polyimide, polyester, PET (polyethylene terephthalate) or paper are used as substrates.
Basically, the process can be broken down into four simple steps:
- Design and mask creation: First, the sensor is designed. Experts determine how it should look and function. A print template or print file is then created, which is the basis for printing.
- Printing the conductive ink: The conductive ink is applied to a carrier material (e.g. film) using a printing process (e.g. inkjet printing, screen printing). This creates the fine pathways that later conduct the electrical signals from the sensor.
- Drying and curing: The ink must be dried and cured to ensure that the printed strips remain conductive. This is often done with the help of heat or UV light.
- Assembly and testing: The printed sensor is integrated into the end product (e.g. a smartphone, a car part). Finally, the sensor is tested to ensure that it works properly.