Functional and Freeform Inkjet Printing

Inkjet-printed conductive traces for printed electronics produced with industrial inkjet printing technology

Digitally printed electronics, biomaterials, and component decoration.

Demand for flexible and cost-efficient production processes is increasing across industries – from electronics manufacturing and medical implants to the decorative design of complex product surfaces.

Conventional analog printing and coating processes are increasingly reaching technological and economic limits, especially where high flexibility and product variety are required.

Industrial inkjet printing technology enables the digital fabrication and functionalization of electronic and medical components, as well as high-resolution digital printing on freeform surfaces – a field that PROFACTOR has been systematically researching and developing for industrial applications for over ten years.

The result is scalable, flexible printing processes that enable sophisticated designs and functional component properties, reduce process steps, and significantly shorten time to market.

3D-Printed Electronics

Using industrial printheads, conductive and dielectric inks are deposited layer by layer onto rigid or flexible substrates of various materials.

The 3D printing process is fully compatible with conventional electronics design data.

Ideally suited for prototyping and small series production of multilayer PCBs, sensors, antennas, smart textiles, and more.

Digital printing on freeform surfaces

Curved surfaces are printed in high resolution using industrial print heads, with print data and print path precisely aligned.

Conventional robots or multi-axis systems move the component and/or the print head.

Freeform inkjet printing is suitable for the graphical decoration of technical components or consumer products, from batch-size-one to large-scale production.

3D-Printed biomaterials

Biocompatible materials (biomaterial inks) are digitally printed onto (3D) surfaces using industrial print heads.

When applied to ceramic base components, patient-specific implants are created to optimize cell growth.

For use in diagnostics, bioactive layers are digitally printed onto test substrates to precisely influence biological reactions.

Technologies

Piezo Inkjet Technology

Piezo inkjet printheads (drop-on-demand) enable the digital and highly precise application of tiny ink droplets onto a surface.

Industrial print heads feature hundreds of parallel nozzles, allowing high-resolution images or structures to be printed contactlessly, quickly, and reliably onto flat or curved surfaces.
Suitable for both thin decorative layers and multilayered, functional 3D structures.

Inkjet Inks

Inkjet-compatible inks are characterized by low viscosity and small particle sizes, or specialized flow characteristics, enabling the controlled formation of tiny droplets.

In water- or solvent-based inks, conductive, dielectric, biomaterial, or pigment nanoparticles or finely dispersed, or dyes are dissolved, forming the printed layer after curing.

Inks are selected together with the printhead depending on surface properties and the desired print quality. For this, we work closely with a variety of established ink manufacturers.

Substrates & Materials

As a contactless printing process, inkjet enables printing on almost any rigid, flexible, porous, or stretchable substrate and component, whether flat or curved.

Depending on the application, pre- and post-treatment steps such as cleaning, surface activation, or sintering may be necessary to ensure properties like adhesion, scratch resistance, or conductivity.

Solutions for Innovative Products

Developing the core technology in-house enables us to tailor processes individually to meet specific customer requirements.

3D-Printed Electronics: Antennas and Sensors

Integration of digitally printed sensors and antennas together with conventional signal processing electronics on a single component.

High flexibility regarding base material and design changes.

Scalable across all stages – from prototyping to small series production.

3D-Printed Circuit Boards (PCBs)

Fully digitally printed multilayer PCBs according to your design specifications.

Short development cycles enabled by digital manufacturing and simultaneous production of different electrical designs.

Custom manufacturing from prototypes to small series with short lead times. Made in Europe.

Freiform Inkjet-Druck mit robotergestütztem Drucksystem zur digitalen Dekoration komplexer Bauteiloberflächen

Freeform Inkjet Printing Technology

Processes and systems for the digital decoration of freeform surfaces and complex component geometries.

Robotic or multi-axis systems move the print head or the component to enable precise single-colour or multicolour printing.

Process steps are individually adapted to material properties, including pre- and post-treatment, to ensure reproducible print quality.

Substitution of existing analog coating processes with flexible, digital printing technologies.

Biomaterial inkjet printing technology

Development of (bioresorbable) biomaterial inks for digital printing.

Process development for 3D printing of structured functional layers on patient-specific implants for human medicine.

Digital surface functionalization of lab-on-a-chip components for diagnostics using biologically active materials.

Application Areas

Selected examples demonstrate the diverse applications of our inkjet printing technology.

Together with customers and partners from a wide range of industries, PROFACTOR has developed and successfully realized digitally printed electronics systems, medical implants, and industrial components.

Nahaufnahme einer goldenen mehrlagigen Leiterplatte (PCB) mit Mikrochip und Kontaktpins – Elektronik Prototyp und Platinenlayout im Detail.

Fully 3D-printed multilayer printed circuit boards (PCBs)

3D gedruckte Sensorstrukturen auf Textilien für medizinische Patientenüberwachung mittels funktionalem Inkjet-Druck

3D-printed sensors for integration into textiles for patient monitoring

Transparente 3D-gedruckte Mikrostruktur-Gitterwürfel neben Lithografie-Masken auf Glas – Prototypen für Mikrooptik und additive Fertigung.

Functionalization of ceramic parts for patient-specific implants

Robotergestützter Freiform Inkjet-Druck zur digitalen Dekoration eines Schuhs auf einer komplexen Oberfläche

Freeform inkjet printing for the decoration of shoes

PROFACTOR, Your Technology Partner

From innovative ideas to industrial implementation.

Requirements and Feasibility[

After a confidential exchange of information, we clarify objectives and initial requirements.

If needed, we test the basic feasibility in the laboratory using an initial selection of inks and practical test prints.

This creates a shared understanding of the solution concept, along with a rough cost estimate, as a basis for the following development stages.

Process Development, Demonstrators, and Small Series Production

If necessary, we develop a customized printing process based on our (3D) inkjet technology and selected inks. This involves design optimizations and regular coordination with you.

We print your components (PCBs, sensors, antennas, etc.) as prototypes. This allows you to comprehensively evaluate their function and quality.

Subsequently, we manufacture small series for comprehensive field testing or for direct use in batch-size-one products.

Customized Printing Technology and Systems

For digital printing on curved surfaces, we develop and build customized inkjet printing systems tailored to your requirements.

We combine our inkjet technology with robotic or multi-axis systems for efficient decoration, customization, or functionalization of free-form components.

Proven Partnerships

Selected customers and partners from joint development and industrial projects.

Current Research Projects

Our technology portfolio is based on a large number of research projects with national and international partners from industry, universities and research institutions.

We combine practical requirements with global trends to develop forward-looking research initiatives. Together with our partners, we develop printing technologies for high-quality and efficient additive manufacturing.

Our research focuses on: