3D printing for the mass production of electronics

Aerosol Jet technology, an additive manufacturing process developed by Optomec, is being used by contract manufacturer Lite-On Mobile Mechanical for the high-volume production of electronic devices. The company has pioneered a 3D Direct Printing (3DP) solution that enables 3D antenna patterns and other functional electronics to be integrated into virtually any mechanical structure or cover.

Lite-On first purchased Aerosol Jet technology to develop prototypes for its OEM customers, which include communication device, personal care and automotive brands. The digitally driven Aerosol Jet-based 3DP process provides full design flexibility, with quick iteration and minimum lead time for last-minute changes. It additionally ensures optimal placement and performance and allows for slimmer product designs.

After successfully implementing Aerosol Jet in prototype environments, Lite-On expanded its usage and has now deployed multiple production machines in Guangzhou, China, operating 24/7 printing conformal electronics onto millions of consumer devices. Since the 3DP process requires no plating or special resins, logistics are simplified and production costs are lowered.

The open architecture of the Aerosol Jet hardware allows configurations to be optimised for specific production needs. The implementation at Lite-On leverages a series of Aerosol Jet print modules spread across multiple 5-axis motion platforms, configured to handle common smartphone and tablet form factors. Each machine is able to print a wide range of common electronics materials at a rate of millions of units per year, enabling next-generation applications in consumer electronics, automotive, aerospace and smart IoT devices.

“With the flexibility provided by Aerosol Jet technology, our 3DP systems can print sensors, antennas and other functional electronics onto plastic components and covers as well as metal die-cast insert-moulded polymer frames and even onto glass panels and ceramic materials,” said Henrik Johansson, senior manager, technology development antennas, Lite-On. “We see Aerosol Jet as a strategic component of our 3DP solution, which has enabled us to expand into new markets.”

Photo courtesy of Lite-On Mobile Mechanical.