altiumlive: imse: creating smart surfaces with … · 2020. 1. 27. · imse solution 3mm part...
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ALTIUMLIVE: IMSE: CREATING SMART SURFACES WITH ELECTRONIC FUNCTIONALITY
Sini RytkyVP, Product Management Munich
Jan 17th, 2019Tuomas HeikkiläSenior Specialist, Hardware
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IMSE = Injection Molded Structural Electronics
IMSE integrates printed circuitry and discrete electronic components inside plastics creating a single-part assembly with a revolutionary design freedom.
• Electronic functions in 3D contours
• Part thickness only 2 mm+
• One electromechanical interface
• Single-part construction, no assembly in production
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IMSE Process
IMSE technology turns plastics into smart surfaces by integrating flexible printed circuitry and electronic components like LEDs into 3D injection molded structures using standard high-speed manufacturing methods and equipment. IMSE products can be 1- or multi-film structures.
3.Forming 3D shape with components
4.Injection molding final
single-part assembly
2. Mounting components on
flat film
1.Printing decoration, wiring,
touch controls, and antennas
*SMART* IN-MOLD LABELLING (IML)MANUFACURING FLOW *SMART* IN-MOLD LABELLING (IML)
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IMSE Part Structure
PR
OC
ES
SIN
G
Decorative A Surface• IML Film or Natural Materials• Decorative inks
Everything is injection molded to one-piece
assembly
A surface electronics• Conductive inks• Dielectric inks• SMT electronics
Plastic Resin• PC, TPU
B surface electronics• Conductive inks• Dielectric inks• SMT electronics
Functional B Surface• IML film
Designs may be 1- or 2-film
Designs may be 1- or 2-film Electronics may be on one or both films
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Smart Surfaces
• Integrate electronic functionality
with existing surfaces and in space-
limited locations where
conventional electronics fail to be
integrated
• Unlimited form factors
• Improved performance
• Make dumb smart
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Evolution to the Shape and Build of Products
• Reduce the level of individual parts in
assembly, reduce assembly phases and reduce
maintenance of individual items in your
inventory and systems
• Up to 90% less part thickness
• Up to 80% less weight
• No assembly
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Durability and Reliability
• Wash & Go
• Safe from moisture and debris
• -40 to +85 temperatures
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How it was done before
Overhead Control Panel
Traditional electronics assembly
45mm part thickness
64 parts + PCBA
650 gram weight
Doing it with IMSE
Overhead Control Panel
IMSE solution
3mm part thickness ~93% reduced thickness
1 molded part + small PCBA
200 gram weight ~70% reduced weight
Comparison
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Building Blocks
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CONNECTWi-Fi
BTNFC
LOOK & FEELSurface materialsSurface finishing
SENSEProximityGesture
TOUCHButtonSlider
ILLUMINATEIndicator
IconAmbient
IMSE BUILDING
BLOCKS
MATERIALS & COMPONENTS
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IMSE Part
Control Electronics
Control Software
External
Wireless
Messaging
LIN
Messaging
Drivers for
Building
Blocks
Connector
interface from
IMSE to Control
Electronics
Flat Cable
In-Mold
Connector
Connector
interface from
Control
Electronics to
End System
Customer
Specific
Connector
System
Integration
from Control
Software to
End System
Not part of
TT standard
delivery
IMSE System
IMSE System Elements
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Making Products
How building blocks are used to create products.
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Customer Case
Suunto Smart Connector
10K+ twist and bends50+ washing cycles
www.movesense.com
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Smart Ashtray Cover
3mm thicknessSeat heater controlAir ventilation control
www.quin-automotive.com
Customer Case
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Wooden Door Trim
3mm thicknessIlluminated seat controls
www.novem.com
Customer Case
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Learn the rules like a pro so you can
breake them like an artist.
Pablo Picasso
How to Digitalize Adoption of New Technologies?
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TactoTek Design & Manufacturing
• TactoTek designs and validates product according to customer requirements
• Manufacturing @TactoTek
Licensed Manufacturing
• TactoTek designs product according to customer requirements
• Manufacturing @ Customer factory with TactoTek IMSE Builder™
Licensed Design & Manufacturing
• Customer designs the product with TactoTek IMSE Designer™
• Manufacturing @ Customer factory with TactoTek IMSE Builder™
Disrupting Technology, Supporting Markets
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Why Specific Tools for IMSE Design
▪ IMSE Designer enables independent designers to create TactoTek IMSE products using familiar design and simulation tools
▪ Traditionally electronics and mechanics design are separate processes, where flat or flexible PCB is assembled inside mechanics and assembled together
▪ In IMSE the entire design process is working in parallel on the same part, the film, which contains the UI graphics, part geometry and electronics - hence the traditional design guidelines do not apply in many instances
▪ The full film assembly, including electronics, is thermoformed and injection-molded which in turn challenges the simulations for electromagnetic performance, thermoforming and injection mold-flow
Altium Designer 19 incorporatesdesign guidelines and DRC for IMSE
design.
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IMSE SPECIFICS IN
ELECTRONICS DESIGN
Identify cross-overs automatically
Apply dielectrics automatically
Prevent errors in component placing
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IMSE vs. Traditional PCB’s
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Thin, Plastic Substrate• FR4 vs. Plastic film• Component footprint
Trace Resistance• 99.9% copper vs. Silver flakes & polymers• Trace dimensions vs. current capacity
Dielectric Design• Dielectrics for bridges
2D 3D
3D Surface• 2D vs. 3D• Location of components at stretching areas
IMSE Design for Manufacturing• Trace & component distance
from gate point
Comparing IMSE with Traditional PCB
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IMSE Electronics Design Flow
Component librarySchematic
Layout
High level design flow similar with PCB
Component librarySchematics
Layout
High level design flow similar with PCBIMSE Specific Details
IMSE Certified Components
Schematics
Layout Design SimulationsFabrication
Files
IMSE Layout Design
Guidelines
Input FilesMechanics 2D
Tooling 2DAntennaLED Map
UI Graphics
Engineers and CAD tools collaborating
OK
NOK
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IMSE Design Example
Interface
3D Shape
MechanicalFeature
CapacitiveButton
Traces & Wiring
Dielectrics
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How have we done it?PCB layer stack in IMSE
Via between 1st and 2nd conductive ink layers
Mechanical layers for
dielectric design
Manual DRC
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Reshape.
Restyle.
Reinvent.
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Revolution
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Yesterday:
2D
Today:
3D
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This is not the future.
www. .com
This is today.
Catch the wave with us !