| 1. | EXECUTIVE SUMMARY |
| 1.1. | Flexible hybrid electronics: Analyst viewpoint (I) |
| 1.2. | Analyst viewpoint (II) |
| 1.3. | What is flexible hybrid electronics (FHE)? |
| 1.4. | Motivating factors for FHE |
| 1.5. | Comparing benefits of conventional and flexible hybrid electronics |
| 1.6. | Overcoming the flexibility/functionality compromise |
| 1.7. | Predicted manufacturing trends for FHE |
| 1.8. | Supplier opportunities created by FHE adoption |
| 1.9. | Non-technological barriers to FHE adoption |
| 1.10. | Where does FHE have a sufficient value proposition? |
| 1.11. | FHE value proposition for different applications |
| 1.12. | Technology gaps and potential solutions for FHE to meet application requirements |
| 1.13. | Materials, components, and manufacturing methods for FHE |
| 1.14. | Component attachment materials for FHE: Conclusions |
| 1.15. | Flexible ICs: Conclusions |
| 1.16. | Flexible batteries for FHE: Conclusions |
| 1.17. | Energy harvesting for FHE: Conclusions |
| 1.18. | Flexible substrates for FHE: Conclusions |
| 1.19. | Conductive inks for FHE: Conclusions |
| 1.20. | R2R manufacturing for FHE: Conclusions |
| 1.21. | Use cases for FHE |
| 1.22. | FHE for electronic skin patches: Conclusions |
| 1.23. | FHE for e-textiles: Conclusions |
| 1.24. | FHE for smart packaging: Conclusions |
| 1.25. | FHE for IoT devices (industrial and domestic): Conclusions |
| 1.26. | FHE for large area LED lighting: Conclusions |
| 1.27. | Additive circuit prototyping with FHE: Conclusions |
| 1.28. | FHE circuit area forecast by application sector |
| 1.29. | FHE revenue forecast by application sector |
| 2. | INTRODUCTION |
| 2.1. | Overview |
| 2.1.1. | FHE combines the benefits of conventional and purely printed electronics |
| 2.1.2. | What counts as FHE? |
| 2.1.3. | Commonality with other established and emerging electronics methodologies |
| 2.1.4. | Printed electronics is additive, but can be analogue or digital |
| 2.1.5. | Multilayer PCBs - technically challenging for FHE |
| 2.1.6. | Overcoming the flexibility/functionality compromise |
| 2.1.7. | Readiness of FHE for different application sectors |
| 2.1.8. | FHE value chain: Many materials and technologies |
| 2.1.9. | Benefits of printing conductive interconnects |
| 2.1.10. | SWOT analysis: Flexible hybrid electronics (FHE) |
| 2.1.11. | Ensuring reliability of printed/flexible electronics is crucial |
| 2.1.12. | Digitization in manufacturing facilitates 'FHE-as-a-service' |
| 2.1.13. | Alternative routes to FHE manufacturing |
| 2.1.14. | Standards for FHE |
| 2.2. | Recent FHE developments |
| 2.2.1. | VTT improves FHE pilot line capabilities (I) |
| 2.2.2. | FHE manufacturing of capacitive touch interfaces and flexible lighting. |
| 2.2.3. | VTT improves FHE pilot line capabilities (II) |
| 2.2.4. | Emergence of contract manufacturer TracXon for flexible hybrid electronics (FHE) |
| 2.2.5. | CPI focuses on printed/hybrid electronics for healthcare applications |
| 2.2.6. | Jabil develops FHE prototypes for healthcare applications |
| 2.2.7. | Growing interest in utilizing copper ink for FHE (I) |
| 2.2.8. | Growing interest in utilizing copper ink for FHE (II) |
| 2.3. | Government funded projects and research centers |
| 2.3.1. | Government funded projects dominate |
| 2.3.2. | NextFlex focus on prototype system development |
| 2.3.3. | Funding of Nextflex project calls |
| 2.3.4. | Holst Centre develops |
| 2.3.5. | IMEC collaborates with Pragmatic to develop an 8-bit flexible microprocessor |
| 2.3.6. | Liten CEA-Tech develops printed batteries and transistors |
| 2.3.7. | Korea Institute of Machinery and Materials develops R2R transfer method |
| 2.3.8. | EU Smart2Go project aims to integrate energy harvesting into wearable devices |
| 2.3.9. | Swedish research center RISE offers hybrid electronics prototyping |
| 2.3.10. | ITRI develops armband for contactless EMG detection |
| 2.3.11. | Recent US government funded FHE projects: 2022 |
| 2.3.12. | Recent US government funded FHE projects: 2021 |
| 3. | MARKET FORECASTS |
| 3.1. | Overview |
| 3.1.1. | Market forecasting methodology: Applications |
| 3.1.2. | Market forecasting methodology: FHE proportion |
| 3.1.3. | FHE circuit area forecast by application sector |
| 3.1.4. | FHE circuit area forecast by application sector (2023, 2028, 2033) |
| 3.1.5. | FHE revenue forecast by application sector |
| 3.1.6. | FHE revenue forecast by application sector (2023, 2028, 2033) |
| 3.1.7. | FHE circuit area forecast for automotive applications |
| 3.2. | Forecasts by application sector |
| 3.2.1. | FHE revenue forecast for automotive applications |
| 3.2.2. | FHE circuit area forecast for consumer applications |
| 3.2.3. | FHE revenue forecast for consumer applications |
| 3.2.4. | FHE circuit area forecast for energy applications |
| 3.2.5. | FHE revenue forecast for energy applications |
| 3.2.6. | FHE circuit area forecast for healthcare/wellness applications |
| 3.2.7. | FHE revenue forecast for healthcare/wellness applications |
| 3.2.8. | FHE circuit area forecast for infrastructure / buildings / industrial applications |
| 3.2.9. | FHE revenue forecast for infrastructure / buildings / industrial applications |
| 4. | MATERIALS, COMPONENTS AND MANUFACTURING METHODS |
| 4.1. | Overview |
| 4.1.1. | Materials, components, and manufacturing methods for FHE |
| 4.2. | Component attachment methods and materials |
| 4.2.1. | Component attachment material: Introduction |
| 4.2.2. | Differentiating factors amongst component attachment materials |
| 4.2.3. | Low temperature solder enables thermally fragile substrates |
| 4.2.4. | Low temperature solder alloys |
| 4.2.5. | Comparing electrical component attachment materials |
| 4.2.6. | Photonic soldering gains traction |
| 4.2.7. | Component attachment materials (for printed/flexible electronics): SWOT analysis |
| 4.2.8. | Low temperature full metal interconnects with liquid metal solder microcapsules |
| 4.2.9. | Solder facilitates rapid component assembly via self- alignment |
| 4.2.10. | Electrically conductive adhesives: Dominant approach for flexible hybrid electronics |
| 4.2.11. | Example of conductive adhesives on flexible substrates |
| 4.2.12. | Durable and efficient component attachment is important for FHE circuit development |
| 4.2.13. | Field-aligned anisotropic conductive adhesive reaches commercialization |
| 4.2.14. | Conductive paste bumping on flexible substrates |
| 4.2.15. | Component attachment materials for FHE roadmap |
| 4.2.16. | Component attachment materials: Readiness level |
| 4.2.17. | Component attachment materials for FHE: Conclusions |
| 4.3. | Flexible ICs |
| 4.3.1. | Flexible ICs: Introduction |
| 4.3.2. | Fully printed ICs have struggled to compete with silicon |
| 4.3.3. | Current approaches to printed logic |
| 4.3.4. | Fully printed ICs for RFID using CNTs emphasize design flexibility |
| 4.3.5. | Metal oxide semiconductors: An alternative to organic semiconductors |
| 4.3.6. | Benefits |
| 4.3.7. | Investment into metal oxide ICs continues |
| 4.3.8. | Larger flexible ICs can reduce attachment costs |
| 4.3.9. | Flexible metal oxide ICs target applications beyond RFID such as smart packaging |
| 4.3.10. | Thinning silicon wafers for flexibility without compromising performance |
| 4.3.11. | Manufacturing flexible 'silicon on polymer' ICs |
| 4.3.12. | Embedding thinned silicon ICs in polymer |
| 4.3.13. | Embedding both thinned ICs and redistribution layer in flexible substrate |
| 4.3.14. | Silicon thinning process would need to be inserted into existing value chain |
| 4.3.15. | Where will bespoke or natively flexible processes be required? |
| 4.3.16. | Comparing flexible integrated circuit technologies |
| 4.3.17. | Flexible ICs: SWOT analysis |
| 4.3.18. | Roadmap for flexible ICs technology adoption |
| 4.3.19. | Flexible ICs: Conclusions |
| 4.4. | Printed and mounted sensors |
| 4.4.1. | Printable sensing materials: Introduction |
| 4.4.2. | What defines a printed sensor? |
| 4.4.3. | Overview of specific printed/flexible sensor types |
| 4.4.4. | Drivers for printed/flexible sensors |
| 4.4.5. | FHE enables IoT monitoring and 'ambient computing' |
| 4.4.6. | Screen printing dominates printed sensor manufacturing |
| 4.4.7. | Polymeric piezoelectric materials receive increasing interest |
| 4.4.8. | Sensing for industrial IoT |
| 4.4.9. | Sensing for wearables/AR |
| 4.4.10. | Companies looking to incorporate printed/ flexible sensors often require a complete solution |
| 4.4.11. | Printable temperature sensors |
| 4.4.12. | MEMS for flexible hybrid electronics |
| 4.4.13. | Printable sensor materials: SWOT analysis |
| 4.4.14. | Printed sensor materials: Readiness level assessment |
| 4.4.15. | Printed sensors for FHE: Conclusions |
| 4.5. | Thin film batteries |
| 4.5.1. | Thin film batteries and power sources |
| 4.5.2. | 'Thin', 'flexible' and 'printed' are separate properties |
| 4.5.3. | Major battery company targets printed/flexible batteries for smart packaging |
| 4.5.4. | Printed flexible batteries in development for smart packaging |
| 4.5.5. | Printed and coin cell battery integration for FHE smart tags |
| 4.5.6. | Using a thin film battery as an FHE substrate |
| 4.5.7. | FHE as a power conditioning circuit |
| 4.5.8. | Technology benchmarking for printed/flexible batteries |
| 4.5.9. | Flexible batteries: SWOT analysis |
| 4.5.10. | Application roadmap for printed/flexible batteries |
| 4.5.11. | Flexible batteries for FHE: Conclusions |
| 4.6. | Energy harvesting for FHE |
| 4.6.1. | Energy harvesting for FHE: Introduction |
| 4.6.2. | Epishine is leading the way in solar powered IoT, but no attempt to integrate with FHE yet |
| 4.6.3. | Perovskite PV could be cost-effective alternative for wireless energy harvesting |
| 4.6.4. | Saule Technologies: Perovskite PV developer for indoor electronics |
| 4.6.5. | Energy harvesting from EM spectrum |
| 4.6.6. | Thermoelectrics as a power source for wearables |
| 4.6.7. | Flexible PV for energy harvesting: Readiness level assessment |
| 4.6.8. | Flexible PV for energy harvesting: SWOT analysis |
| 4.6.9. | Power sources for FHE roadmap by application sectors |
| 4.6.10. | Energy harvesting for FHE: Conclusions |
| 4.7. | Flexible substrates |
| 4.7.1. | Substrates for printed/flexible electronics: Introduction |
| 4.7.2. | Cost and maximum temperature are correlated |
| 4.7.3. | Properties of typical flexible substrates |
| 4.7.4. | Comparing stretchable substrates |
| 4.7.5. | Thermoset stretchable substrate used in multiple development projects |
| 4.7.6. | External debris and protection/cleaning strategies |
| 4.7.7. | Paper substrates: Advantages and disadvantages |
| 4.7.8. | Specialist paper substrates can have properties comparable to polymers |
| 4.7.9. | Sustainable RFID tags with antennae printed on paper |
| 4.7.10. | Dimensional stability: Importance and effect of environment |
| 4.7.11. | Manipulating polyester film microstructure for improved properties |
| 4.7.12. | Heat stabilization of polyester films |
| 4.7.13. | Roadmap for flexible substrate adoption |
| 4.7.14. | Flexible substrates for FHE: Conclusions |
| 4.8. | Conductive inks |
| 4.8.1. | Conductive inks: Introduction |
| 4.8.2. | Challenges of comparing conductive inks |
| 4.8.3. | Segmentation of conductive ink technologies |
| 4.8.4. | Conductive ink companies segmented by conductive material |
| 4.8.5. | Market evolution and new opportunities |
| 4.8.6. | Balancing differentiation and ease of adoption |
| 4.8.7. | Interest in novel conductive inks continues |
| 4.8.8. | Copper inks gaining traction but not yet widely deployed |
| 4.8.9. | Companies continue to develop and market stretchable/thermoformable materials |
| 4.8.10. | Higher nanoparticle ink prices offset by conductivity |
| 4.8.11. | Conductive inks: SWOT analysis |
| 4.8.12. | Conductive inks: Readiness level assessment |
| 4.8.13. | Conductive inks for FHE: Conclusions |
| 4.9. | Printing methods and R2R manufacturing |
| 4.9.1. | R2R manufacturing: Introduction |
| 4.9.2. | Can R2R manufacturing be used for high mix low volume (HMLV)? |
| 4.9.3. | What is the main commercial challenge for roll-to-roll manufacturing? |
| 4.9.4. | Examples of R2R pilot/production lines for electronics |
| 4.9.5. | Commercial printed pressure sensors production via R2R electronics |
| 4.9.6. | Emergence of a contract manufacturer for flexible hybrid electronics (FHE) |
| 4.9.7. | Applying 'Industry 4.0' to printed electronics with in-line monitoring |
| 4.9.8. | Applications of R2R electronics manufacturing |
| 4.9.9. | Comparison of printing methods: Resolution vs throughput |
| 4.9.10. | R2R manufacturing: SWOT analysis |
| 4.9.11. | R2R manufacturing: Readiness level |
| 4.9.12. | R2R manufacturing for FHE: Conclusions |
| 5. | USE CASES FOR FHE |
| 5.1. | Overview |
| 5.1.1. | Use cases for FHE |
| 5.1.2. | Technology gaps and potential solutions to meet application requirements |
| 5.2. | Electronic skin patches |
| 5.2.1. | Benefits of electronic skin patches as a form factor |
| 5.2.2. | Development from conventional boxed to flexible hybrid electronics to fully stretchable |
| 5.2.3. | Electronic skin patches within wearable technology progress |
| 5.2.4. | Skin patch applications overview |
| 5.2.5. | Interest in skin patches for continuous biometric monitoring continues |
| 5.2.6. | Material requirements for an electronic skin patch |
| 5.2.7. | Material suppliers collaboration has enabled large scale trials of wearable skin patches |
| 5.2.8. | Progress in using liquid metal alloys as stretchable inks for wearable electronics |
| 5.2.9. | Growing interest in liquid metal wiring for stretchable electronics (II) |
| 5.2.10. | 'Full-stack' material portfolios reduce adoption barriers |
| 5.2.11. | R2R pilot line production of skin patch with FHE. |
| 5.2.12. | Printed batteries in skin patches |
| 5.2.13. | Electronic skin patch manufacturing value chain |
| 5.2.14. | Electronic skin patch manufacturing process |
| 5.2.15. | Offering S2S and R2R production enables different order sizes |
| 5.2.16. | Increased demand for wearable/medical manufacturing leads to expansion plans |
| 5.2.17. | Utilizing existing screen-printing capabilities for electronic skin patches |
| 5.2.18. | GE Research: Manufacturing of disposable wearable vital signs monitoring devices |
| 5.2.19. | NextFlex: Utilizing electronics in silicone to make more comfortable skin patches |
| 5.2.20. | Key points: Materials for electronic skin patches |
| 5.2.21. | FHE for electronic skin patches: SWOT analysis |
| 5.2.22. | FHE for electronic skin patches: Conclusions |
| 5.3. | E-textiles |
| 5.3.1. | E-textiles can utilize FHE for component integration |
| 5.3.2. | E-textiles represent a small market share for biometric monitoring |
| 5.3.3. | Industry challenges for e-textiles |
| 5.3.4. | Three competing approaches to e-textile manufacturing |
| 5.3.5. | Conductive ink requirements for e-textiles |
| 5.3.6. | Permeability of particle-free inks enable direct metallization of fabric to form e-textiles |
| 5.3.7. | Embedding electronics in a box avoids washability issues |
| 5.3.8. | Patterning and design may be used to supplement capabilities of printed conductive inks |
| 5.3.9. | Comparing conductive inks in e-textiles |
| 5.3.10. | Challenges with conductive inks in e-textiles |
| 5.3.11. | Sensors used in smart clothing for biometrics |
| 5.3.12. | Electronic components are joined by connectors |
| 5.3.13. | Connector designs and implementations |
| 5.3.14. | Overview of components in e-textiles |
| 5.3.15. | Commercial progress with e-textile projects |
| 5.3.16. | FHE for e-textiles: SWOT analysis |
| 5.3.17. | FHE for e-textiles: Conclusions |
| 5.4. | Smart packaging |
| 5.4.1. | Smart packaging: An ideal candidate for FHE |
| 5.4.2. | Motivation for smart packaging: Logistics and safety |
| 5.4.3. | Motivation for smart packaging: Improving sales and consumer engagement |
| 5.4.4. | Current status of smart packaging market |
| 5.4.5. | RFID tags with printed silver antennas on paper substrates |
| 5.4.6. | Copper ink for RFID antennas offers reduced costs and improved sustainability? |
| 5.4.7. | FHE with printed batteries and antennas for smart packaging |
| 5.4.8. | Simpler FHE circuits achieve easier market traction |
| 5.4.9. | Established semiconductor manufacturer explores FHE circuits for smart packaging |
| 5.4.10. | Smart packaging requirements can be fulfilled with simpler, cheaper ICs. |
| 5.4.11. | FHE controls OLEDs for smart packaging |
| 5.4.12. | Smart-packaging to improve pharmaceutical compliance |
| 5.4.13. | Smart tags with a flexible silicon IC |
| 5.4.14. | 'Sensor-less' sensing of temperature and movement with |
| 5.4.15. | FHE for smart packaging: SWOT analysis |
| 5.4.16. | FHE for smart packaging: Conclusions |
| 5.5. | IoT devices (industrial and domestic) |
| 5.5.1. | IoT devices (industrial and domestic): An emerging opportunity for FHE, |
| 5.5.2. | Industrial asset tracking/monitoring with FHE |
| 5.5.3. | Integrating a flexible IC within a multimodal sensor array |
| 5.5.4. | Capacitive sensors integrated into floors and wall panels |
| 5.5.5. | Integrated electronics enable industrial monitoring |
| 5.5.6. | Multi-sensor wireless asset tracking system demonstrates FHE potential. |
| 5.5.7. | Passive UHF RFID sensors for structural health monitoring |
| 5.5.8. | FHE for IoT devices: SWOT analysis (I) |
| 5.5.9. | FHE for IoT devices (industrial and domestic): Conclusions |
| 5.6. | Lighting |
| 5.6.1. | FHE for large area lighting: Introduction |
| 5.6.2. | FHE contract manufacturer produces large area LED lighting |
| 5.6.3. | R2R etching competes with FHE |
| 5.6.4. | R2R manufactured LED lighting on foil |
| 5.6.5. | Directly printed LED lighting (I) |
| 5.6.6. | Directly printed LED lighting (II) |
| 5.6.7. | FHE for large area lighting: SWOT analysis |
| 5.6.8. | FHE for large area LED lighting: Conclusions |
| 5.7. | Prototyping |
| 5.7.1. | Additive circuit prototyping with FHE: An introduction |
| 5.7.2. | Additive circuit prototyping landscape |
| 5.7.3. | Prototyping flexible 2D circuits with additive electronics |
| 5.7.4. | Multilayer circuit prototyping |
| 5.7.5. | Affordable pick-and-place for prototyping and small volume manufacturing |
| 5.7.6. | Readiness level of additive circuit prototyping |
| 5.7.7. | Additive circuit prototyping with FHE: Conclusions |
| 6. | COMPANY PROFILES |
| 6.1. | American Semiconductor |
| 6.2. | ACI Materials |
| 6.3. | Alpha Assembly |
| 6.4. | BeFC |
| 6.5. | Boeing |
| 6.6. | Coatema |
| 6.7. | Copprint |
| 6.8. | CPI |
| 6.9. | DoMicro |
| 6.10. | DuPont |
| 6.11. | Elantas |
| 6.12. | Electroninks |
| 6.13. | GE Healthcare |
| 6.14. | Henkel |
| 6.15. | Heraeus |
| 6.16. | Holst Center |
| 6.17. | Indium |
| 6.18. | InnovationLab |
| 6.19. | Inuru |
| 6.20. | IOTech |
| 6.21. | Jabil |
| 6.22. | Laiier |
| 6.23. | Liquid Wire |
| 6.24. | Molex |
| 6.25. | Muhlbauer |
| 6.26. | Nano Dimension |
| 6.27. | NextFlex |
| 6.28. | Optomec |
| 6.29. | Panasonic Electronic Materials |
| 6.30. | PragmatIC |
| 6.31. | PrintCB |
| 6.32. | PVNanoCell |
| 6.33. | Safi-Tech |
| 6.34. | Saralon |
| 6.35. | Screentec |
| 6.36. | Sun Chemical |
| 6.37. | Sunray Scientific |
| 6.38. | TraXon |
| 6.39. | VTT |
| 6.40. | Wiliot |
| 6.41. | Ynvisible |
| 6.42. | Ynvisible/Evonik/EpishineContact IDTechEx |