New production paradigms

Every bit of energy that is saved goes a long way in securing the needs of present and future generations. So also every bit of material that necessitates more mining of some metal or ore. Finally, any innovations to production processes that reduce wastage and minimise energy and material is welcome.

Flexible circuits can be found in many devices where space and weight considerations are dominant in the design of electronics: in cars, in cameras and video equipment, in mini-computers or in inkjet printers. According to the business consultancy Frost & Sullivan, sales in this area will grow to more than $16 billion by the year 2014.

No wonder research in this area is leaping in bounds. A new reel-to-reel technology for the production of flexible circuits and biosensors, known as "P3T," which is shorthand for "Plasma Printing and Packaging Technology" involves considerably fewer process steps than existing processes, and it conserves raw materials.

During production of circuits for an RFID antenna, you often have to etch away between 50 and 80 percent of the copper used. This results in considerable amounts of copper scrap that either has to be disposed or reprocessed using relatively elaborate methods. The IST approach is different: there, scientists use the additive process to apply the structures they want directly to the substrate sheeting.

Researchers are currently working very hard to improve the individual processes involved in the manufacture of flexible circuit boards and biosensors. They are closely scrutinizing all of the P3T production steps -- from plasma printing to assembly and coordinating all of the processes with one another in a production line.

Technological improvisations are headed in the right direction, what is lagging is the change in attitudes, especially when it comes to individual lifestyles. We still are used to a season of plenty.