Functional Printing: Unlocking Future Opportunities
In our first part on this topic, we introduced functional printing and its potential to replace traditional manufacturing methods. Then we explored the advantages and limitations of different printing technologies used in functional printing. Now we look ahead: What are the biggest challenges preventing widespread adoption? Which industries stand to benefit the most? How can functional printing scale up to meet demand?
While the technology of functional printing has been on the verge of breaking through for over a decade, there are strong indications that functional printing is finally gaining momentum.
Challenges Holding Back Functional Printing
Quality Control & Inspection
Many functional print applications—such as printed electronics or medical sensors—can only be fully tested after assembly. This makes it difficult to detect and correct defects early in production, increasing waste rates and costs.
Solution: Advanced inline inspection systems and AI-driven quality control are being developed to improve defect detection.
Certification & Compliance
Most functional print applications fall under strict industry regulations (e.g., electronics, medical devices, automotive parts). Unlike traditional printing, functional print production must meet high safety, durability, and environmental standards.
Solution: Close collaboration with regulatory bodies and standardisation of materials and processes will help accelerate adoption.
Scaling Up Production
Paradoxically, one of the biggest challenges in functional printing is that printing is too productive for current market demand. For example, research from the University of Chemnitz suggests that a single narrow-web or B1 sheetfed press could produce all the solar panels needed worldwide.
Solution: More flexible, multi-application production lines and on-demand manufacturing models will allow companies to switch between different printed products as needed.
High Material Costs & Process Complexity
Functional printing often requires speciality inks and substrates, which are significantly more expensive than standard printing materials. In addition, each production line must be customised for specific applications, making large-scale investment risky.
Solution: Advances in material science and modular production systems will help lower costs and increase efficiency.
Industries Poised to Benefit from Functional Printing
Functional printing has long since proven its ability to transcend traditional printing applications. But which sectors recognise this potential and are actively driving its further development? There are new opportunities for innovative applications, particularly in areas such as lightweight construction, flexibility, miniaturisation and intelligent surfaces. The following overview shows the sectors in which functional printing can be used:
Printed Electronics – Smart, Lightweight, and Flexible
Functional printing is enabling the production of thin, flexible electronics, leading to innovations such as:
- RFID tags for logistics and supply chain tracking
- Flexible circuit boards for wearables and medical devices
- Printed sensors for industrial automation
Renewable Energy & Smart Surfaces
Printed solar cells and energy-harvesting surfaces are becoming more efficient, opening up possibilities for:
- Thin-film solar panels for buildings, vehicles, and portable energy solutions
- Printed batteries and supercapacitors for energy storage
- Smart windows with adjustable light and heat filtering
Medical & Biotech Applications
The healthcare industry is exploring functional printing for biocompatible, low-cost, and scalable solutions, such as:
- Biosensors for disease detection and health monitoring
- Printed drug delivery patches that release medication over time
- Lab-on-a-chip diagnostics, enabling rapid testing for infections or genetic conditions
Automotive & Aerospace – Lightweight and High-Performance Components
Functional printing allows the production of lightweight, high-performance parts, improving fuel efficiency and durability.
- Printed antennas for smart vehicles
- Lightweight sensors for aircraft and satellites
- Conductive coatings for electromagnetic shielding
What’s Next for Functional Printing?
The future of functional printing is not about a single breakthrough moment but rather continuous, step-by-step progress. As industries move toward Industry 4.0, the demand for low-cost, high-efficiency manufacturing solutions will keep growing.
Key Developments to Watch
More Hybrid Production Models – Combining functional printing with traditional manufacturing to increase scalability.
AI-Driven Quality Control – Reducing waste and improving precision through machine learning and automation.
Customisable, On-Demand Production – Functional print service providers could offer multi-application production lines to meet changing market needs.
Sustainable Materials – Development of bio-based conductive inks and recyclable substrates to reduce environmental impact.
Functional printing has come a long way, and while challenges remain, its role in the future of manufacturing is undeniable.
