Modern electronic devices are becoming increasingly integrated into our daily lives, yet traditional rigid printed circuit boards (PCBs) often limit design possibilities. Flexible electronics is a breakthrough technology that overcomes these limitations, enabling the creation of devices that can bend, fold, or stretch without losing functionality.

This revolutionary field is transforming the way we think about electronics design. Flexible circuits are not only lighter and more durable than conventional solutions, but they can also take on unconventional shapes, conforming to curved surfaces or moving parts. In practice, this allows electronics to be placed where it was previously impossible – from wearable biomedical sensors to smart vehicle surfaces and foldable displays.

What is Flexible Electronics?

Flexible electronics, also known as flex circuits, is a technology that allows electronic components to be mounted on bendable substrates such as polyimide (PI), polyethylene terephthalate (PET), or polycarbonate (PC). Unlike traditional rigid PCBs made from materials like epoxy laminates, flexible circuits can be bent, folded, or stretched, providing designers with greater freedom in creating devices with unconventional shapes.

Conductive elements in flexible electronics are manufactured using different technologies. The most common approaches include printing with conductive inks based on silver, copper, or graphene nanocrystals, or depositing ultra-thin metal layers via vapor-phase techniques onto flexible substrates. Both methods produce conductive traces that maintain electrical continuity even under significant deformation.

Unique Properties and Advantages of Flexible Electronics

Flexible electronics features a unique set of properties that distinguish it from traditional technologies. Key advantages include:

  • Flexibility and adaptability – circuits can bend, fold, and conform to irregular surfaces without losing functionality. Modern solutions withstand tens of thousands of deformation cycles, enabling installation on moving parts or curved surfaces.
  • Lightweight and ultra-thin – flexible circuits made on polyester or polyimide films are up to ten times lighter than conventional PCBs. Thickness can be only a few dozen micrometers, allowing integration in areas inaccessible to traditional electronics.
  • Exceptional mechanical durability – flexible materials better withstand impacts, vibrations, and mechanical stress, eliminating issues such as solder joint cracking common in rigid boards.
  • Stability under harsh conditions – substrates like polyimide resist extreme temperatures and aggressive chemical environments, ideal for industrial and aerospace applications.
  • Biocompatibility – certain materials can safely contact human skin, enabling implants, medical sensors, and smart health-monitoring patches.
  • Efficient production – functional printing technologies, such as screen printing or inkjet printing with conductive inks, allow reel-to-reel mass production at significantly lower cost than traditional photolithography processes.
  • Sustainable development – printed manufacturing consumes less energy and produces less waste. Materials like PET can be recycled, and reduced raw material usage makes flexible electronics more environmentally friendly.

Flexible electronics thus offer a unique combination of mechanical and electronic properties, enabling the creation of innovative, efficient, and versatile devices.

Applications of Flexible Electronics

Flexible electronic circuits are increasingly used in industries that require combining electronic functionality with mechanical flexibility, from precise medical applications and advanced industrial systems to everyday consumer devices.

Medical and Biotechnology

  • Wearable biosensors that monitor vital signs without restricting movement.
  • Flexible electrodes in ECG and EEG systems for better skin contact and patient comfort.
  • Smart medical patches that deliver drugs while monitoring physiological responses via integrated sensors and wireless communication.
  • Flexible diagnostic patches improve telemedicine and remote patient monitoring.
  • Flexible strain gauges in rehabilitation allow precise measurement of movement range and muscle activity, with EMG sensor systems optimizing therapy programs in real time.

Automotive Industry

  • Flexible pressure sensors in seats detect passenger presence and position, adjusting safety systems.
  • Heated mats provide comfort in seats, steering wheels, and panels, and prevent freezing of mirrors, cameras, and ADAS sensors.
  • Flexible heating systems in electric vehicles warm batteries and drive components for optimal performance in cold conditions.
  • Flexible substrates (PI, PET, TPU) allow mats of any shape, perfectly fitting complex vehicle geometries.
  • Curved touch panels and conformable antennas support intuitive interfaces and V2X communication.
  • Embedded climate sensors automatically control cabin microclimate. Flexible strain gauges monitor structural and suspension fatigue in real time.

Robotics and Industrial Automation

  • Electronic skins on robot grippers detect contact and precisely control grip force.
  • Flexible sensors in collaborative robots (cobots) enable safe human interaction.
  • Human-machine interfaces respond to touch, pressure, and gestures, enhanced by flexible conductive materials.
  • Flexible strain gauges monitor robot structures in real time, enabling predictive maintenance and increased production reliability.

Wearable Electronics and Stretchable Systems

  • Flexible circuits enable unconventional device forms, from foldable smartphones to smart clothing with sensors and LEDs.
  • Fitness bands integrate heart rate sensors, accelerometers, and wireless communication, providing all-day comfort.
  • Stretchable electronics handle deformations over 100%, using composite materials and mesh structures with silver nanowires, graphene, or EGaIn alloys, integrating with fabrics and skin without restricting movement.
  • Flexible touch keyboards can be rolled and carried in pockets while maintaining full functionality, thanks to conductive printing technology.

In-Mold Electronics (IME) Technology

  • IME allows embedding electronic components during plastic molding.
  • Integrates electronics with housings and panels, reducing mechanical connections and components.
  • Produces lightweight, moisture-resistant systems with integrated touch buttons, backlighting, and sensors.
  • Applications include automotive, household appliances, consumer electronics, and aerospace, enabling lighter, reliable, and aesthetically pleasing interfaces.

Flexible Electronics in Qwerty Membrane Keyboards
Our interfaces exemplify the use of flexible printed circuits to create precise switches responding to pressure through controlled contact of conductive layers.

  • Proprietary conductive printing methods ensure reliability in demanding industrial conditions.
  • Silver- and carbon-based pastes maintain stable electrical conductivity over thousands of bending and pressing cycles.
  • Single-layer flexible circuits allow complex, low-profile switching systems suitable for harsh environments.
  • Additional functionalities, such as resistive force-detection traces and capacitive proximity sensors, can be integrated.

These advanced solutions, combined with our expertise in materials and printing processes, deliver interfaces with exceptional functionality and durability.