Green roll-to-roll manufacturing of low-cost high-performance large area flexible electronics

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Green roll-to-roll (R2R) manufacturing can enable eco-friendly and economical fabrication of modern flexible electronics. With rapidly growing markets for flexible electronic displays, solar cells, electronic skin and the internet of things (IoT), key challenges for massive scale manufacturing need to be addressed, including cost, performance, environmental friendliness of fabrication processes and reusability of materials and substrates. Achieving highly conductive, reliable and low-cost electric interconnects and related electronic devices is critical for the development of industrial scale R2R production of flexible electronics. However, solutions for stable, highly conductive materials often rely on expensive source materials (e.g., silver) and produce toxic waste arising from post processing and etching. Considering the exponential growth in electronic waste, it is imperative to look for solutions that are more friendly to environment and still meet the requirements of the growing electronics industry. This project brings a strong team of researchers and laboratories at UBC in collaboration with a world-leader in flexible electronics, TF Massif, located in Burnaby, BC, to develop solutions that address these critical challenges. The project will focus on development of complementary solutions for direct print nano-inks, vacuum deposition techniques, post processing and ablation materials that enable use of multi-layered, highly conductive and patternable interconnects and electronic devices on a variety of flexible substrates including polyethylene terephthalate (PET), polyimide (PI), clear PI and other flexible substrates that are bio-sourced and biodegradable. The project will investigate the processes and associated in-depth material properties that can provide high conductivity, bonding to flexible substrates and stability in frequent mechanical bending, stretching and exposure to environmental changes and chemicals. By developing advanced processes and nano-inks that are amenable to massive area and low-cost flexible electronics, this project opens significant opportunity for TF Massif and other Canadian industry leaders to develop a globally competitive advantage and define future markets in green R2R manufacturing and create jobs for Canadians.