Functional printing: Choosing the right technology is crucial

The key printing technologies for functional printing

A closer look at the key printing technologies for functional printing and their strengths and weaknesses.

1. Screen printing – high layer thicknesses, high-precision coating

Screen printing is one of the most widely used processes in functional printing, particularly for thick-film applications such as printed electronics, solar cells and sensors.

Advantages:

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

Disadvantages:

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

Best suited to conductive inks, sensors, OLED displays and solar cells

2. Inkjet printing – digital, contact-free and material-efficient

Inkjet printing is becoming increasingly important in the field of functional printing, as it is a digitally controlled process that does not require printing plates or screens. It is particularly useful when working with expensive functional fluids, as it minimises waste.

Advantages:

• No printing plates or stencils required – ideal for rapid prototyping and bespoke designs
• The contactless process reduces the risk of damaging sensitive materials
• High precision, making it suitable for microfluidic devices and printed circuits

Disadvantages:

• Limited to low-viscosity inks – many functional inks need to be modified for use in inkjet printing
• Drying and adhesion problems, particularly on non-porous surfaces
• Slower throughput compared to screen printing or gravure printing

Best suited to RFID antennas, microfluidics, biosensors and flexible electronics

3. Gravure printing – high-speed production for thin functional layers

Rotogravure printing is known for its high speed and continuous production. This makes it a suitable process for large-area functional printing. It is particularly well-suited to thin, uniform layers such as barrier layers and conductive films.

Advantages:

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

Disadvantages:

• Expensive equipment – engraved cylinders must be manufactured for each design
• Limited flexibility, making it unsuitable for small production runs or frequent design changes

Best suited to printed batteries, capacitors and high-volume electronic components

4. Flexographic printing – flexible and scalable

Flexographic printing is an established technology for packaging printing – but can also be used for functional printing applications. This process offers a good balance between cost, flexibility and production speed.

Advantages:

• Works well on a wide range of substrates, including flexible films
• Scalable for mass production at moderate cost
• Good resolution for fine patterns and circuit traces

Disadvantages:

• Requires flexographic printing plates, which increases production costs for small batches.
• Ink transfer may be uneven with high-viscosity functional inks.

Best suited to printed circuit boards, printed electronics and smart packaging

Choosing the right technique

Every functional printing application has its own specific requirements. There is therefore no one-size-fits-all solution. Nevertheless, the following recommendations can be made:

• Do you need thick conductive layers? → Screen printing is the best choice
• Do you work with expensive materials? → Inkjet printing minimises waste
• Are you scaling up 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.

So what’s next?

Choosing the right printing technology is a crucial factor in successfully turning an idea into a functional product. However, whether functional printing will become widely adopted also depends crucially on whether we can overcome a number of very practical challenges. In a future blog post, we will explore the new technical approaches available to address these challenges and how they will shape the future of electronics, medical technology and industrial manufacturing.