A new approach to printed circuit component fabrication
As the automotive industry increasingly shifts toward electrification and smart systems, the demand for sustainable, scalable, and cost-effective flexible electronics is growing rapidly. A promising alternative to traditional chemical wet etching and silver printing has emerged: dry phase patterning using aluminum. This method offers automotive manufacturers significant environmental, economic, and functional advantages.
Rethinking conductive patterning in automotive electronics
The two production technologies, Wet Etching or printing silver has long dominated printed circuit fabrication. However, Silver presents key limitations in cost, recyclability, and material sustainability. In contrast, aluminium—abundant, affordable, and recyclable—remains underutilised due to technical barriers in conventional printing processes. Chemical etching has limitations in sustainability with its use of harsh chemicals and the costly waste handling as well as it high energy consumption.
Dry Phase Patterning (DPP) introduces a shift in how circuits are fabricated.
DPP is an unique, patented mechanical process that can create flexible circuit boards in a safe, continuous, and highly efficient manner, eliminating the need for wet chemistry, masks, waste handling or printing silver.
Advantages for automotive applications
• Cost-Efficiency: Aluminium is significantly less expensive than silver, lowering material costs for high-volume production. And the effective process has proven to be cost-effective in comparison with wet etching, reducing costs between 30-60% and in some cases even higher cost savings when replacing silver printing.
• Environmental Benefits: The dry process reduces chemical waste and energy consumption. A report from Fraunhofer Institute shows a 99% reduction both in carbon footprint and electricity used compared to conventional wet etching.
• Robustness: Aluminium circuits exhibit excellent durability, making them ideal for harsh automotive environments.
• Design Flexibility: The technology allows rapid design changes and customisation without tooling changes.
Technical Insight into the DPP Process Dry Phase Patterning is a mechanical milling manufacturing method that produces flexible circuits without any liquid inks or chemical etching. Instead of printing conductive material, DPP starts with a flex laminate, (a thin foil of metal, usually aluminium, laminated on a flexible substrate), and physically patterns it in a continuous roll-to-roll process.
The technique can be summarised in two steps:
1. A patterned “cliché” presses onto the metal-coated film, which protrudes the unwanted material.
2. A milling wheel then mechanically removes the excess metal foil from all areas except the pattern. The unwanted metal is lifted away as scrap, leaving behind the circuit design on the substrate.
This patented process brings you instant advantages, such as increased cost efficiency, reduced lead times, and environmentally friendly, sustainable high-volume production of Flex-PCB components.
Multiple use cases for automotive
There are several use cases for Dry Phase Patterning FPCB components in the automotive industry, e.g. thermal applications like heaters ranging from heaters for batteries all the way to mirror heaters. Other examples of applications are CCS (Cell Connecting Systems) for sensing the battery cells, LED-applications (perfect for interior and front grill) and FPC connectors, to just name a few examples of applications.
As automotive electronics evolve, material and process innovation will be key. Dry phase patterning stands out as a viable solution to the pressing cost and sustainability challenges of flexible electronics. Its compatibility with aluminium opens the door for greener and more affordable automotive innovations.
Words by Tommy Höglund, sales and marketing manager at DP Patterning. Find out more at www.dppatterning.com or by contacting tommy.hogland@dppatterning.com / +46 72 245 46 74.