Functional Printing: Choosing the Right Technology

In our first blog post on this topic, we introduced functional printing and looked at the steps a product goes through from idea to market. We will now take a closer look at which printing technologies are suitable for this.

Unlike conventional print applications, where visual quality is the main focus, functional printing requires precise material deposition to achieve specific electrical, optical, or mechanical properties. This makes the choice of printing technology a crucial factor in scalability, efficiency, and product performance.

Let’s take a closer look at the leading technologies used in functional printing, along with their strengths and limitations.

Screen printing is one of the most widely used methods in functional printing, especially for thick-layer applications like printed electronics, solar cells, and sensors.

Advantages:

• Can print thick layers in a single pass, reducing material waste
• Works with high-viscosity functional inks, including conductive pastes
• Suitable for flexible substrates, making it ideal for printed electronics

Challenges:

• Limited resolution compared to inkjet or gravure printing
• Not ideal for ultra-fine patterns or rapid design changes

Best for: Conductive inks, sensors, OLED displays, and solar cells

Inkjet printing is gaining interest in functional printing due to its digital nature —eliminating the need for printing plates or screens. It’s particularly useful when working with expensive functional fluids, as it minimises waste.

Advantages:

• No need for plates or stencils — ideal for rapid prototyping and custom designs
• Contactless process, reducing the risk of damaging delicate materials
• High precision, making it suitable for microfluidic devices and printed circuits

Challenges:

• Limited to low-viscosity inks — many functional inks need modification to be jettable
• Drying and adhesion challenges, especially on non-porous surfaces
• Slower throughput compared to screen or gravure printing

Best for: RFID antennas, microfluidics, bio-sensors, and flexible electronics

Gravure printing is known for high-speed, continuous production, making it a strong candidate for large-scale functional printing. It’s particularly effective for thin, uniform coatings such as barrier layers and conductive films.

Advantages:

• High-speed process, suitable for roll-to-roll production
• Excellent ink transfer, even for low-viscosity functional fluids
• Consistent layer uniformity, ideal for printed electronics

Challenges:

• Expensive setup — engraved cylinders must be manufactured for each design
• Less flexible for small-scale production or frequent design changes

Best for: Printed batteries, capacitors, and high-volume electronic components

Flexo printing is a well-established technology in packaging, but it’s also being adapted for functional print applications. It offers a good balance between cost, flexibility, and production speed.

Advantages:

• Works well with a variety of substrates, including flexible films
• Scalable for mass production with moderate costs
• Good resolution for fine patterns and conductive traces

Challenges:

• Requires flexo plates, adding production costs for small-scale runs
• Ink transfer can be inconsistent with high-viscosity functional inks

Best for: Conductive circuits, printed electronics, and smart packaging

Every functional printing application has its own requirements. Therefore, there is no standardised solution for all applications. Nevertheless, the following recommendations can be derived:

• Do you need thick conductive layers? → Screen printing is the best choice
• Are you processing expensive materials? → Inkjet printing minimises waste
• Are you scaling your production? → Gravure printing offers high throughput
• Do you print on flexible substrates? → Flexographic printing offers a good balance between cost and flexibility

Which process is the right one ultimately depends on the required resolution, material compatibility, production volume and costs. In many functional printing projects, several printing processes are also combined to achieve the best results.

Choosing the right printing technology is a key factor in successfully turning an idea into a functional product. However, whether or not functional printing takes off on a larger scale will also depend on whether a number of very practical challenges can be overcome. In a future blog post, we will look at the new technical approaches available to solve these challenges and how they will shape the future of electronics, medical technology and industrial manufacturing.