Flexible Hybrid Electronics: Next-Generation Integration Technology

Flexible Hybrid Electronics (FHE) combines the performance of traditional rigid electronic components with the flexibility of printed electronics. This innovative technology creates electronic circuits by printing dielectric, conductive, and semi-conductive layers on flexible substrates, with the ability to mount rigid components such as microcontrollers. Avery Dennison Performance Tapes provides specialized pressure-sensitive adhesive solutions designed to address the unique challenges of FHE manufacturing and assembly.

  • For those new to FHE

    Flexible Hybrid Electronics represent the evolution of electronics manufacturing, allowing circuits to bend and conform to different shapes while maintaining functionality. This requires specially engineered adhesive solutions that work seamlessly with printed electronic inks and components.

The Three Essential Elements of Printed Electronics


Avery Dennison Performance Tapes' solutions address all three critical components of Flexible Hybrid Electronics:

Functional Inks


These specialized inks form the electrical pathways in printed electronics, with each type offering different levels of conductivity, flexibility, performance and cost-effectiveness.

  • Metallic conductive inks including silver (Ag) and copper (Cu)
  • Non-metallic conductive materials such as carbon, PEDOT, graphene and polyaniline
  • Dielectric inks for insulation and circuit protection

 

Substrate Materials


The substrate is the foundation of flexible electronics, providing mechanical support while allowing the necessary flexibility for the application.

  • Natural substrates including paper, cardboard, silk, and starch-based materials
  • Synthetic substrates such as PET, PEN, PC, TPU, and PDMS films
  • Specialty substrates including glass with ITO coatings

Print Technologies


These printing methods deposit conductive and functional materials in precise patterns to create electronic circuits on flexible substrates.

  • Contact printing methods including screen, gravure, offset, and flexographic printing
  • Non-contact methods such as inkjet and aerosol jet printing

Avery Dennison Performance Tapes develops pressure-sensitive adhesive systems specifically tested for compatibility with these essential elements, ensuring optimal electrical performance and mechanical reliability throughout the product lifecycle. Without compromising on any additional key functionalities/requirements in the application.


Benefits and Applications of Printed Electronics


Flexible Hybrid Electronics offer significant advantages over traditional rigid electronics, including simpler manufacturing processes, more sustainable materials, lower production costs, and the ability to conform to various shapes and surfaces.

The ongoing expansion of the Internet of Things (IoT) has created new applications within industries for printed electronics. These technologies enable smart homes, healthcare products, and advanced solutions for mobility and connectivity. Driven by digitization and IoT, the printed electronics market is accelerating with shorter product life cycles and changing customer requirements. 


Key Application Markets for Flexible Hybrid Electronics


Medical Devices and Healthcare

  • Wearable health monitors and ECG electrodes
  • Smart patches for drug delivery
  • Blood pressure monitors and insulin pumps
  • Skin patches and smart glasses
  • Defibrillator components

Automotive and Transportation

  • Seat heating systems with PTC (Positive Temperature Coefficient) technology
  • Steering wheel heating and HOD applications
  • Window defoggers and climate control components
  • Conformable sensors for vehicle monitoring
  • In-cabin control systems and displays
  • Sensor interfaces for ADAS systems

Consumer Electronics and Displays

  • Flexible displays and foldable smartphones
  • Activity monitors and fitness wearables
  • Smart textiles and e-textiles
  • Smart watches and sleep monitoring devices
  • Touch interfaces and membrane switches

Energy and Construction

  • Printed batteries and solar cells
  • Smart HVAC controls and building automation
  • Environmental monitoring sensors and displays
  • Printed heaters for floor warming applications
  • Flexible photovoltaic integration

Industrial IoT and Packaging

  • Smart packaging with embedded sensors
  • RFID antennas and e-labels
  • RF sensors for supply chain monitoring
  • Cold chain monitoring systems
  • Anti-counterfeiting solutions
  • Environmental monitoring sensors

PTC Heater Technology: A Focus on Innovation


Positive Temperature Coefficient (PTC) heater technology represents one of the most promising applications for Flexible Hybrid Electronics, particularly in automotive, consumer, and industrial markets.

How PTC Technology Works in practice


  • As temperature increases, the material's resistivity increases

  • Increasing resistivity leads to lower power consumption

  • Physical mechanism: expansion of binder/resin interrupts conductive tracks

  • Percolation threshold: material switches from conductive to insulating state

Key Benefits of PTC Heaters


  • Self-limiting temperature regulation without thermal cut-off mechanisms

  • Energy-saving operation that adjusts power consumption automatically

  • Self-adaptive power distribution across the heating area

  • Improved safety and reliability for heating applications

Common PTC Heater Applications


  • Automotive seat heating 

  • Home appliance heating elements 

  • Floor heating systems

  • Battery thermal management systems

  • Defrosting and defogging applications


Avery Dennison Performance Tapes provides specialized adhesive solutions designed specifically for PTC heater assembly, ensuring optimal thermal transfer, electrical performance, and long-term reliability in demanding environments.

PSA Tapes for Printed Electronics: Research and Development


Pressure-sensitive adhesive (PSA) tapes play a critical role in the assembly and performance of Flexible Hybrid Electronics. Avery Dennison Performance Tapes has developed specialized formulations designed specifically for compatibility with printed electronic components.

PSA Requirements for Printed Electronics

  • Strong adhesion on PET, PC and PU films commonly used in flexible electronics

  • Strong chemical and environmental resistance to ensure durability in various conditions

  • Good balance between peel and shear properties for reliable performance

  • Compatible with conductive inks with minimal impact on electrical characteristics

Avery Dennison PSA Tape Constructions for Flexible Electronics


Solvent-based Pure Acrylic (Ultra High Adhesion)

  • Transfer tapes (MS 21091, MS 21092)

  • Double-coated PET (MS 70003, MS 70006, MS 70009, FT 7397)

  • Single-coated PET (MS 0387, MS 0392, FT 0300)

UV Cross-linked Pure Acrylic (Membrane Switch Range)

  • Transfer tapes (FT 2150, FT 2151)

  • Double-coated PET (FT 7349, FT 7352)

  • Double-coated scrim (FT 7961)

  • Double-coated non-woven (FT 7250)

Solvent-based Pure Acrylic (Low VOC)

  • Transfer tapes (FT 21182, FT 21183)

  • Double-coated PE foam (FM M2705, FM M2713, FM M2757)

This comprehensive testing ensures our adhesive solutions maintain electrical performance throughout the product lifecycle.



The Future of Flexible Hybrid Electronics

The market for flexible electronics is growing rapidly, and our team is dedicated to developing and pairing the right specialized adhesive solutions needed to support new applications and manufacturing methods.

With the  Internet of Things in full expansion, Flexible Hybrid Electronics are becoming increasingly important across multiple industries to stay connected, data gathering, and ensure manufacturing efficiencies.. Avery Dennison Performance Tapes is committed to supporting this growing market with innovative adhesive solutions.

Our Technical Support and Development Services

  • Specialized material selection consulting based on your specific application requirements
  • Compatibility testing with your conductive inks and substrate materials
  • Process optimization support for integrating adhesives into your manufacturing workflow
  • Comprehensive electrical characterization and reliability testing
  • Aging and environmental testing to validate long-term performance
  • Access to Avery Dennison's global expertise in pressure-sensitive adhesive technology

Key Advantages of FHE Manufacturing

  • Less complex manufacturing compared to conventional electronics (no etching, photolithography, or wire bonding)
  • More environmentally sustainable materials and processes
  • Lower processing and manufacturing costs
  • Superior flexibility and conformability for integration into various forms and surfaces
  • Compatibility with high-volume production methods

Our other Innovations

Contact us for answers, quotes or samples

Jarne Machiels

Application & Technical Service Engineer

Jarne Machiels is the Application & Technical Service Engineer responsible for Germany as well as (Automotive) Electronics Market at Avery Dennison Performance Tapes Europe.  Thanks to his previouses roles in the printing - and adhesive tape converting industry, he has an extensive know-how to understand your technical needs for each application. In parallel, Jarne focuses on technical innovation within Avery Dennison - being expertised in (printed) electronics, heating applications and automotive safety systems. 

jarne.machiels@eu.averydennison.com
www.linkedIn.com/in/jarne-machiels