Functional Printing: A New Era for Manufacturing

Printing has long said to die and be replaced by other technologies. However, printing technologies are now being used to replace traditional manufacturing processes. This emerging field, known as functional printing, is enabling the production of electronic components, smart surfaces, and advanced coatings — opening up entirely new possibilities for industries such as electronics, healthcare, and renewable energy.

But what exactly is functional printing, and what does it take to bring a functional print product to market?

Functional printing differs from traditional printing because it is not about aesthetics. Instead, it involves depositing patterned layers of functional materials to create electrical, optical, or mechanical properties on a substrate.

Some of the most exciting applications include:

• Printed electronics: Sensors, RFID antennas, and flexible circuits
• Energy solutions: Solar cells, batteries, and energy-harvesting devices
• Smart surfaces: Optical filters, light-emitting displays, and interactive materials
• Medical and biotech applications: Biosensors, lab-on-a-chip devices, and drug delivery patches

Unlike conventional manufacturing methods such as etching, deposition, and milling, functional printing offers a cost-effective, scalable alternative for producing advanced materials.

The road to commercialising a functional print product is complex. Each project requires customised development, typically following these five key stages:

1. Concept & Feasibility Study

At this stage, companies assess whether a functional print solution is technically possible and economically viable. Can a printed layer replace a traditionally manufactured component? Are the materials and production costs reasonable?

2. Prototyping

Once a concept is proven feasible, small-scale prototypes are created using lab-scale printing equipment. These prototypes help refine the ink formulations, substrates, and printing processes before scaling up.

3. Pilot Production

This stage bridges the gap between prototype and industrial production. Here, the product is manufactured in limited quantities using scaled-up equipment, while also undergoing certification, compliance testing, and real-world validation.

4. Integration into Manufacturing

For a functional print product to be commercially viable, it must fit into existing production workflows. This stage involves optimising quality control, automation, and process stability to ensure high yields and minimal waste.

5. Full-Scale Industrial Production

The final step is mass production. However, functional printing presents a unique challenge: printing processes are often too productive for current market demand. A single narrow-web or sheetfed press could theoretically produce all the world’s printed solar panels. Costs and returns must therefore be weighed up carefully.

This has prompted discussions about more flexible production models, including independent functional print service providers that can adapt production lines for different applications.

Functional printing is already transforming electronics, energy, and healthcare, but the journey from lab to large-scale manufacturing is filled with challenges. In another Blogpost, we’ll explore how different printing technologies contribute to functional printing — highlighting their advantages and limitations.