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5-2010 An Investigation of Fundamental Competencies for Printed Electronics John Jacobs Clemson University, [email protected]

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AN INVESTIGATION OF FUNDAMENTAL COMPETENCIES FOR PRINTED ELECTRONICS

A Thesis Presented to the Graduate School of Clemson University

In Partial Fulfillment of the Requirements for the Degree Master of Science Graphic Communications

by John Jay Jacobs May 2010

Accepted by: Dr. Samuel T. Ingram, Committee Chair Dr. Liam O’Hara Mr. Chip Tonkin

i ABSTRACT

A survey was taken of professionals in the printed electronics industry to

determine the basic educational requirements the industry had of a student graduating

with a degree in graphic communications or printing sciences. A test was conducted of

graphic communication seniors graduating in May 2010 to determine their fundamental

knowledge of printed electronics. Data obtained from the industry survey was used to determine the relevant components of a basic printed electronics education. The data obtained from the graduating senior examination determined their areas of knowledge of printed electronics. The needs identified from the industry survey were compared to the areas of knowledge of graphic communications graduating seniors. The knowledge deficiencies of graduating students were identified, and analyzed. It was determined that present graphic communications education is insufficient to meet the needs of the printed electronics industry. Further research was proposed to update graphic communication education to meet the needs of the printed electronics industry.

ii DEDICATION

This work is dedicated to the two most influential people in my life. I dedicate

this work to my wife, Sherri Murphy-Jacobs, whose sacrifice, patience, and continued support has been instrumental in my success. I also dedicate this work to my mother, Jo

Ann C. Jacobs, without whom I would have never learned how to strive for excellence, and whose determination to see me “fulfill my potential” has never wavered.

iii ACKNOWLEDGMENTS

I thank my advisor, Dr. Samuel T. Ingram, for his encouragement, support, and guidance during the completion of this degree.

I thank Gary A. Stura, my employer for the last eighteen years, for his unparalleled support and encouragement. I am grateful for his generosity and trust.

I thank Dr. William Ray, a leader in the field of printed electronics and an inspiration to me.

I thank Dr. Liam O’Hara, who always demanded a little more than my talent could fulfill, but who always took the time to offer words of encouragement, a smile, and support when I needed it.

I thank Chip Tonkin, Carole Jones, Linda Kanaley, Nancy Leininger, and Dr.

Nona Woolbright for their help throughout my graduate career.

I thank Dr. Donald Lupo and the FlexTech Alliance for their help in distribution of the industry survey.

iv TABLE OF CONTENTS

Page

TITLE PAGE ...... i

ABSTRACT ...... ii

DEDICATION ...... iii

ACKNOWLEDGMENTS ...... iv

LIST OF TABLES ...... vi

LIST OF FIGURES ...... vii

CHAPTER

I. INTRODUCTION ...... 1

II. PRINTED ELECTRONICS INDUSTRY SURVEY ...... 6

III. PRINTED ELECTRONICS STUDENT EXAMINATION ...... 10

IV. DATA ANALYSIS AND DISCUSSION ...... 11

Survey of Printed Electronics Industry Professionals ...... 11 Examination of Student Knowledge ...... 22 Interviews with Graphic Communications Students ...... 23

V. CONCLUSIONS...... 25

VI. FUTURE RESEARCH ...... 28

APPENDICES ...... 30

A: Tables and Figures for Introduction and Background ...... 31 B: Answers from Survey of Professionals ...... 32 C: Scores from Student Examination ...... 43 D: Student Examination ...... 44

REFERENCES ...... 47

v LIST OF TABLES

Table Page

4.1 Student Knowledge ...... 22

A.1 Eight Year Projections ...... 31

A.2 Printing Industry Growth ...... 31

B.1 Demographic Data ...... 32

B.2 Section 3 Question 1 ...... 33

B.3 Section 3 Question 2 ...... 34

B.4 Section 3 Question 3 ...... 35

B.5 Section 3 Question 4 ...... 36

B.6 Section 3 Question 5 ...... 37

B.7 Section 3 Question 6 ...... 38

B.8 Section 4 Question 1 ...... 39

B.9 Section 4 Question 2 ...... 39

B.10 Section 4 Question 3 ...... 40

B.11 Section 4 Question 4 ...... 40

B.12 Section 4 Question 5 ...... 41

B.13 Section 4 Question 6 ...... 42

C.1 Exam Results ...... 43

vi LIST OF FIGURES

Figure Page

1.1 PE Market Growth ...... 1

2.1 Survey Page 1 ...... 6

2.2 Survey Page 2 ...... 7

2.3 Survey Page 3 Pt.1 ...... 7

2.4 Survey Page 3 Pt.2 ...... 8

2.5 Survey Page 3 Pt.3 ...... 8

2.6 Survey Page 4 Pt.1 ...... 8

2.7 Survey Page 4 Pt.2 ...... 9

4.1 Question 1 Response Chart ...... 11

4.2 Question 1 Average Response Chart ...... 12

4.3 Question 2 Response Chart ...... 13

4.4 Question 2 Average Response Chart ...... 13

4.5 Question 3 Response Chart ...... 14

4.6 Question 3 Average Response Chart ...... 15

4.7 Question 4 Response Chart ...... 16

4.8 Question 4 Average Response Chart ...... 16

4.9 Question 5 Response Chart ...... 17

4.10 Question 5 Average Response Chart ...... 18

4.11 Question 6 Response Chart ...... 19

vii List of Figures (Continued)

Figure Page

4.12 Question 6 Average Response Chart ...... 19

D.1 Exam Page 1 ...... 44

D.2 Exam Page 2 ...... 45

D.3 Exam Page 3 ...... 46

viii CHAPTER ONE

INTRODUCTION

Traditional printing industry and printing education have been primarily focused

on graphics creation and reproduction. Traditional printing education provides instruction

in printing processes, inks and substrates, design software, process color space, expanded

gamut, and spot colors in both design and print. Traditional printing education addresses

issues with process and spot color inks, water based, solvent based and UV or energy

cured inks when used to create graphic images on a substrate. Outside of package

printing, there has been very little industry growth in traditional printing, and some

segments of the printing industry have faced significant declines in the last decade

(Kowal, J. 2008, 2009, 2010). Experts and consumers alike have proclaimed, “Print is dead,” to which they refer to traditional printing and publishing markets (Gomez, J. 2008 pg. 2). Output of traditional printing industry is projected to decline by $19.2 billion and employment in the traditional printing industry is projected to decline by 214,500 people by the year 2018 (Woods, R. 2009). While print is not dead, the historical market and business of print is changing rapidly as new media technologies are adopted (Costa, D.

2009). The traditional printing industry is striving to adapt to the technological and consumer habit changes due to the expansion of e-media. The industry is

Figure 1.1: PE Market Growth

1 searching for new markets and new products through which it can survive.

In the last decade, and especially in the last five years, the printing industry has

discussed, explored, expounded upon, and prophesized about the future of printed

electronics. The potential for printed electronics applications markets is projected to be as

much as thirty billion dollars by the year 2015 (Gasman 2008). Other than packaging,

printed electronics has the highest growth potential of any of the printing industry

segments today.

Printed electronics, for the purpose of this work, is the application of conductive,

semi-conductive, dielectric and electronic components onto a material by means of a

printing process. It might not occur on a conventional press, but the applied product will

be liquid or semi-liquid in form, and will cover a substrate in a pattern (Kenny 2007).

Auxiliary assembly and fabrication, such as the application of adhesives or the placement

of components, may occur off press.

This recent focus and attention on printed electronics has brought this emerging

industry to the attention of the printing industry as a whole, but this attention is long

overdue. The first printed circuit was produced in 1936 by Paul Eisler, and that process

was used for large scale production of radios by the USA during World War II. Printed

circuit technology was released for commercial use in the USA in 1948 (Printed Circuits

Handbook, 1995). In the over half-century since its inception, printed electronics has evolved from the production of printed circuit boards (PCBs), through the everyday use of membrane switches, to today’s RFID, photovoltaic and electroluminescent technologies. It is nearly impossible to look around a modern American household and

2 not see devices that either use printed electronic components or that are the direct result of printed electronic technologies.

Yet, for how common place printed electronics are, few people are aware that their technological, connected, interactive world is based upon the printing of electronically functional inks. Even printing industry professionals do not commonly grasp the breadth of the effect printed electronics has on their world. Printing is still perceived as a graphic industry concerned only with reproducing images and information onto a physical substrate. Printing education, especially undergraduate education, has the same lagging perception by focusing upon commercial printing industries.

Encouragingly, although not commonly understood by general consumer and printing professional alike, awareness of printed electronics is growing. This awareness has spread far beyond technology blogs and reviews, appearing in such established cultural publications as Harper's Magazine. Harper's Magazine, a monthly general-interest magazine of literature, politics, culture, finance, and the arts, has been continuously- published in the United States since 1859. Comments made at the Intelligent Printing &

Packaging Conference, held October 2006 in Cherry Hill, New Jersey, were published in the February 2007 issue of Harper’s Magazine (Sterling, B. 2007).

From 2006 through 2009, commercial printing industry growth in the United

States has been negligible in all areas but flexographic package and label printing (Table

A.2). Market demand for print media is decreasing while the complexity and quality demanded of print media is on the rise; resulting in a market of higher cost, lower volume production. Many commercial printers have turned to value added services, such as

3 variable data printing, mailing services, and database management, to increase

profitability; which further increases the complexity and unit cost of today’s print media.

Generation Y, which began between the year 2000 and 2010, will have less attachment to

paper than previous generations, casting a shadow upon the future growth of printed

paper media such as magazines, newspapers, and books (Romano 2004, pg. 22).

In 2008 printed electronics application markets exceeded 953 million dollars

(Table A.1). Considering the afore mentioned projected market growth of twenty-nine

billion dollars in only seven years, the printed electronics industry will require well

educated employees with knowledge and understanding of printing processes to meet this

potential. Traditionally, printed electronics industry employees have come from material

science, electronic engineering, physics, chemistry, and mechanical engineering

backgrounds; there has been limited need for employees familiar with graphic

communications and printing technologies. However, as the industry strives to push the

limitations of printing processes and to reduce costs of printed electronics by moving to

large scale roll-to-roll production (Lynn 2005), the demand for print savvy employees

will grow.

Dr. William Ray, lead research scientist for Nth Degree Tech, stated that “we want a finished product [graduating graphic communications student] to be a complete technologist–at least from the manufacturing point of view.” Dr. Ray further suggested that students prepared for a career in printed electronics must have a basic, functional understanding of circuitry and electricity beyond V=IR. Students must understand the function of inks used in printed electronics. Students must understand substrates, as they

4 are printed upon and/or used in the construction of multilayer products. Printed electronics are typically accomplished by hybrid printing technologies, so students must have an understanding of all printing processes and how they can be interrelated (Ray

2009).

Based upon the review of literature on the present and future of the printed electronics industry, a research question was formulated: Does current GC education prepare graduates with competencies recognized by industry professionals as necessary measurable skills. To explore this question, a survey of printed electronics industry professionals was conducted to determine the educational needs of the printed electronics industry. To further explore this question, graduating seniors of the graphic communications program at Clemson University were tested for knowledge relevant to printed electronics.

5 CHAPTER TWO

PRINTED ELECTRONICS INDUSTRY SURVEY

Research was conducted utilizing Survey Monkey, an online survey and research resource. Printed Electronics Industry Professionals were contacted through email directly, through intermediary organizations like the FlexTech Alliance, and by survey participants. The survey was conducted over a nine day period.

The survey was broken into four short sections. The first section provided information about and instructions for the survey.

Figure 2.1: Survey Page 1

6 The second section collected demographic data from the respondent.

Figure 2.2: Survey Page 2

The third section collected ratings of educational needs in the printed electronics industry. Respondents were given the ability to elaborate upon their answers or make comments upon the individual survey questions.

Figure 2.3: Survey Page 3 pt.1

7 Figure 2.4: Survey Page 3 pt.2

Figure 2.5: Survey Page 3 pt.3

The fourth section asked open ended questions which respondents could answer as briefly or as completely as they desired.

Figure 2.6: Survey Page 4 pt.1

8

Figure 2.7: Survey Page 4 pt.2

Survey responses were considered valid and complete if all the questions in section three were completed. If a respondent did not answer all the questions in section

three, the entire survey response was removed from the final data.

9 CHAPTER THREE

PRINTED ELECTRONICS STUDENT EXAMINATION

The three page student examination consisted of twenty questions in total (Figure

D.1, D.2, D.3). The exam was divided into two true/false, five multiple choice, two lists,

two matching, and nine short answer questions. The examination tested knowledge of

printed electronic history, printed electronics industry and products, functional inks,

substrates and laminations, design and schematics, electricity, electronics, and quality

assurance equipment.

The exam was administered to the students of Clemson University’s GC480 class in February 2010. The students were instructed to answer as completely as possible, but not to put their names on the examination pages.

10 CHAPTER FOUR

DATA ANALYSIS AND DISCUSSION

Survey of Printed Electronics Industry Professionals

Survey responses were collected from twenty printed electronics industry professionals ranging from materials suppliers to printed electronics manufacturers and industry association leaders (Table B.1). In the educational needs section of the survey respondents rated the importance of each process, skill or knowledge base to the printed electronics industry. The responses to section three of the survey were analyzed by individual responses and average response values.

Figure 4.1: Question 1 Response Chart

11

Figure 4.2: Question 1 Average Response Chart

Fifty-five percent or more of respondents indicated that understanding of offset

lithography, flexography, and rotogravure printing processes were important to essential.

Eight-five percent of respondents indicated that an understanding of screen printing was

important to essential (Figure 4.1 and Figure 4.2). Comments made by respondents

indicated that the survey did not include knowledge of inkjet printing as an option (Table

B.2). This oversight should be corrected in any future investigation of printed electronics

education.

12 Figure 4.3: Question 2 Response Chart

Figure 4.4: Question 2 Average Response Chart

13 Sixty percent of respondents indicated that knowledge of material science was

essential to the printed electronics industry, with forty-five percent of respondents indicating knowledge of organic chemistry and thirty-five percent of respondents indicating inorganic chemistry were essential. Knowledge of electrical engineering was considered very important or essential to fifty-five percent of respondents (Figure 4.3 and

Figure 4.4). Comments from respondents indicated that the survey did not include knowledge of physics as an option (Table B.3). This oversight should be corrected in any future investigation of printed electronics education.

Figure 4.5: Question 3 Response Chart

14 Figure 4.6: Question 3 Average Response Chart

Respondents were divided on the importance of knowledge of Graphic Design software (Figure 4.5), finding knowledge of general business software to be of greater importance and VDP software to be of little importance (Figure 4.6). Functional knowledge of CAD software was considered most important of the software types to the printed electronics industry, rated as important to essential by sixty-five percent of respondents (Figure 4.5 and Figure 4.6). In the comments made by respondents, the

possibility of circuit design software knowledge was mentioned (Table B.4). A review of

software specific to the industry should be made in any future investigation of printed

electronics education.

15

Figure 4.7: Question 4 Response Chart

Figure 4.8: Question 4 Average Response Chart

16

Respondents indicated that an understanding of inks and coatings, substrates, laminates and adhesives were all important to the printed electronics industry (Figure 4.7 and Figure 4.8). Further, knowledge of inks and coatings was considered essential by

sixty percent of respondents, followed closely by the knowledge of substrates in

importance (Figure 4.7). No additional comments were made by respondents about this

topic (Table B.5).

Figure 4.9: Question 5 Response Chart

17 Figure 4.10: Question 5 Average Response Chart

Though divided as to the specific importance the ability to read schematics,

identify electronic components, and trace circuitry (Figure 4.9), fifty-five percent of respondents indicated that those three skills were important to essential to the industry

(Figure 4.10). Comments were made about the importance of understanding electronic testing devices (Table B.6). There was little importance presently given for the skill at programming computer chips. Computer chip programming was considered a “contract manufacturing” function that was post printed electronics.

18 Figure 4.11: Question 6 Response Chart

Figure 4.11: Question 6 Response Chart

Figure 4.12: Question 6 Average Response Chart

19 Respondents expressed limited value in the knowledge of any programming language,

though one outlier did consider such knowledge essential (Figure 4.11). Commentary

provided no insights as to why this talent was not of value, nor was any programming language suggested that might be of value. (Table B.7).

When asked to elaborate upon the educational components desired in the

curriculum of a graphic communications student in regards to printed electronics, the

respondent answers varied widely (Table B.8). The most mentioned areas of interest were

chemistry, material science, physics, and electricity as applied to the printed electronics

industry. Only forty-five percent of the survey respondents chose to provide an answer to

the question.

When asked to elaborate upon class projects that would be of value to the

education of a graphic communications student in regards to printed electronics, forty-

five percent of the respondents answered. There was consensus among nine respondents’ answers (Table B.9) that projects involving printed circuits, functional design, and device assembly would be valuable. Student research into materials, printing techniques…semi- conductive inks was also indicated as important by the respondents (Table B.10).

Only forty percent of respondents offered any opinion as to association or organizational membership that would be of benefit to graphic communications students involved in the printed electronics industry. Organizations mentioned included IEEE,

SGIA, CEA, IPC, and FlexTech Alliance (Table B.11). It might be of more value for the educational institution, such as the Department of Graphic Communications at Clemson

20 University, to obtain and maintain membership in these organizations than it would be for individual students.

Respondents provided different descriptions of the printed electronics industry

(Table B.12). The most common elements of the descriptions of the printed electronics industry included:

• it is a small but growing industry • it requires more scientific knowledge from the average employee than traditional printing industry • it is more concerned about function than appearance • it has vast potential.

Sixty percent of respondents provided insights into the future of the printed electronics industry. Most responses were vague and unspecific, but all agreed that the industry would continue to grow (Table B.13). Responses with specific examples and projections included:

• the belief that inkjet technology would be vitally important • the belief that flexible energy technologies would be at the forefront • the suggestion that breakthroughs in marketing and consumer awareness would be as important as the scientific advancements in determining what impact printed electronics would have in the next ten to twenty years.

21 Examination of Student Knowledge

Thirty-seven graduating seniors were tested on their knowledge of printed electronics history, the industry, functional inks, typical substrates and materials, electricity, electronics, testing and quality assurance equipment, and ability to read schematics. The exam administered to the graduating seniors was a simplified version of the GC451 Functional Materials and Printed Electronics mid-term exam for the Spring

2010 Semester. Of the seniors who took the exam, only one completed it with a passing grade (Table C.1).

Correct Answer Percent Graduating seniors surveyed understood less than per Category PE History 21.62% thirty percent of the knowledge considered important to the Inks 17.12% Substrates 17.30% printed electronics industry by survey respondents. The Schematics 17.37% graduating seniors had the greatest understanding of Electricity 20.00% Electronics 30.63% measurement and testing equipment, and the least Equipment 43.24% Industry 15.83% understanding of the printed electronics industry itself Table 4.1: Student Knowledge (Table 4.1).

Most students were unable to list or describe functional characteristics of inks, properties of substrates, or read schematics. Most students were unable to provide examples of printed electronic products in use day. Most students could not identify different kinds of printed electronic circuits, nor could they accurately define basic electrical concepts like ohms law, voltage and current. Most students were unaware that printed electronics existed prior to the 1970s.

22 Interviews with Graphic Communications Students

Conversations were held with students attending the 2010 TAGA Conference in

San Diego, CA in March about their educational programs and the involvement they have

had in printed electronics. Students from California Polytechnic State University,

Ryerson University, Western Michigan University, Eastern Illinois University, Ball State

University, and Clemson University were among interview subjects.

A Co-President of the CalPoly student chapter of TAGA stated that although she

knew of graduate research being done at CalPoly on printed electronics she knew of no hands on laboratory research was being done by undergraduate students in that program.

According to this Co-President, printed electronics education at the undergraduate level at CalPoly was limited to research of published information on printed electronics.

Students from Ryerson University, Eastern Illinois University, and Ball State

University knew of no printed electronics education or research at their institutions at the

undergraduate or graduate levels. Students from all of these universities expressed a

desire for printed electronics education in their degree programs.

The President of the Western Michigan University student chapter of TAGA

knew about gravure research being done in printed electronics by the professors and

graduate students in that program, but was unaware of any undergraduate involvement. A

faculty member of the Department of Paper Engineering, Chemical Engineering, and

Imaging at Western Michigan University, confirmed the TAGA Chapter President's

observations on their printed electronics education.

23 The only undergraduate students attending the 2010 TAGA Conference who acknowledged any hands on experience with or instruction in printed electronics were from the Clemson University student chapter of TAGA. Students from Clemson

University participated in the production of an electroluminescent circuit for TAGA in

2009. Clemson students were enrolled in GC451 Functional Materials and Printed

Electronics and participated in the design and production of a corrugated book light for

TAGA in Spring 2010.

Informal discussion with students from nearly all ten attending schools indicated an interest in printed electronics, but a near complete lack of knowledge about the subject. The students in general responded with interest and enthusiasm to any presentation on printed electronics given at the conference.

24 CHAPTER FIVE

CONCLUSIONS

The gap between the current educational needs of the printed electronics industry

and the knowledge of the typical graphic communications graduating student is

undeniable. Over fifty percent of the industry respondents indicated that an understanding

of inks, substrates, electricity, electronics, and schematics was important to essential, yet in the student examination the students scored less than a thirty percent understanding of these topics. Present graphic communications and printing science education has not provided the graduating student with a fundamental understanding of printed electronics.

With a projected growth to $30 billion by 2015 (Gasman 2008), the printed electronics industry presents a significant opportunity for educational institutions.

Graduating graphic communications students had median score of twenty one

percent on the knowledge exam (Table C.1). The disparity between knowledge required

by the printed electronics industry and the knowledge obtained from a traditional graphic

communications education suggests that a graphic communications graduate would

require extensive on the job training to become valuable to the industry.

The related area of knowledge not presently valued by the survey respondents,

the ability to program microchips and knowledge of programming languages (Figure 4.9,

Figure 4.10, Figure 4.11, Figure 4.12, Table B.6, Table B.7) may be true for the present,

but may be short-sighted. Researchers from Sunchon National University in Sunchon,

South Korea and Rice University in Huston, TX have built a complete RFID circuit that

requires no additional data chip, although it only stores one bit of information and is the

25 size of a business card (Grossman 2010). In 2007, Soligie Inc. and Thinfilm Electronics

entered into an agreement to combine IPs for soluble memory materials and functional

materials printing to develop printed memory in commercial volumes (Taylor 2007).

Both of these developments in printed electronics are examples of how quickly programmable printed materials may become reality. If the printed material is

programmable, the programming of the circuits will no longer be a secondary, post-print function, but part of the intrinsic design and production of the printed electronic device.

There is indication that the printed electronics industry, presently a small niche as compared to the traditional printing industry, will grow phenomenally in the next twenty years. With the present lack of undergraduate printed electronics education in most graphic communications and printing technology programs, the graduates from these programs are limited in their initial ability to contribute to this growing industry if competencies and related instruction are not developed.

There appears to be student interest in hands on and laboratory experience in printed electronics education. The demand for more education in printed electronics is coming from both the industry and the students. Institutions involved in printing science education have not addressed this need. Institutions involved in printing science education may need to consider developing curricula, whether by adding to existing course requirements or by developing entirely new courses, which addresses the

educational needs of the printed electronics industry. This education need not be in the

latest research and breakthroughs, but could simply provide a clear understanding of

present printed electronics technologies, markets, and products. As the foundational

26 knowledge of printed electronics among students is developed, advanced research and scientific breakthroughs will follow.

27 CHAPTER SIX

FUTURE RESEARCH

The research conducted suggests that development of printed electronic curricula

could start as special projects and research problems for undergraduate and graduate

students alike. These specialty courses could explore methods and techniques in teaching

the subject to determine the most effective ways to provide a foundational knowledge of

printed electronics to the students. Greater awareness of and information on printed

electronics could be introduced into foundational printing courses. The effectiveness of

these efforts could be verified through continued testing of graduating students’ printed

electronics knowledge.

A study of the knowledge of printed electronics of graduating students of

institutions beyond Clemson University could be conducted. A study of student interest

could be conducted to determine in what and to what extent students wish to learn about printed electronics. A study of equipment and software specifically created for printed electronics could be made. A study of employer interest in hiring more printed electronics

educated graphic communications graduates could be conducted. A more comprehensive,

annual or semi-annual survey could be conducted of printed electronics industry professionals to keep abreast of the latest needs, developments and changes in the industry.

A study of the knowledge and awareness of printed electronics by general printing industry professionals could be done. Industry awareness of these efforts may be of key importance to develop industry participation in printed electronics education. Information

28 on efforts and initiatives in printed electronic education could be sent to industry and trade magazines and journals. Efforts could be made to bring more public awareness of printed electronics through school open houses, seminars, and presentations.

29

APPENDICES

30 Appendix A

Tables and Figures for Background and Introduction

Table A.1: Eight Year Projections (Gasman 2008)

Percentage Printing Industry Growth 2006 - 2009 2006-2007 2007-2008 2008-2009 Average Printing & Related activities 1.2 2.6 -0.8 1.0 Commercial Litho 0.9 1.5 -1.8 0.2 Commercial Gravure 0.2 2.7 -2.2 0.2 Commercial Flexo -1.3 8.5 1.8 3.0 Commercial Screen 0.4 -1.7 0.1 -0.4 Quick Printing -0.2 4.2 -0.2 1.3 Digital Printing 1.7 -0.2 -2.6 -0.4 Printing Machinery Mfg 1.4 1.2 1 1.2 *from US Dept. of Labor and US Bureau of Statistics PPI Detailed Reports Table A.2: Printing Industry Growth (Kowal 2008, 2009, 2010)

31 Appendix B

Answers from Survey of Professionals

Company Name Job Title Industry Primary Product/Service Dupont Applications Tech MGr Electroncis Materials Printed Electronics Applied Research Flexible, Printed Materials and Process Development - Laboratory Executive Director Electronics Contract Research Senior Business Manager, LC Specialty Development and manufacturing of EMD Chemicals Inc. and Emerging Technologies Chemicals specialty chemicals DuPont Microcircuit Materials Marketing Manager Electronics Electronic Materials Cambridge Display Intellectual Property Licensing and Technology CEO OLED Rand D OLED/OSC materials Displays, Private Consultant Lighting Technical Consulting flexible nyx project manager electronics prototype design and test Diversified 3M Company Research Specialist Manufacturing HP Eng Electronics Printing and displays Program Manager, Flexible glass & glass Glass substrates for LCD, PV, OLED, Corning Incorporated Substrates ceramics and other large-area electronics Honeywell R&D Manager Semiconductor materials Optomec, Inc Senior Scientist Electronics Printing equipment TECHNICAL DEVELOPMENT FILM TEKRA CORP SPECIALIST CONVERTING POLYMER SUBSTRATES Graphic overlays/Custom control Hallmark Nameplate Director of Engineering Manufacturing panels/Contract Manufacturing Printed Electronics / Hallmark Nameplate Graphic Engineer Nameplates Nameplates Nameplates, Membrane Switches, Graphic Overlays, Contract Hallmark Nameplate, Inc QA Manager Pritign Manufacturing

Printed Nano ePrint Ltd VP Product Management Electronics Printed Logic Functional Materials, Technology Consulting Consultant Displays Consulting and Contracting Cytec Industries Principal Research Fellow Chemical Specialty Chemicals and Materials Table B.1: Demographic Data

32 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important is an understanding of the following printing processes in Printed Electronics? Offset Litho Flexo Gravure Screen Prtng Additional Comments 1 1 1 4 4 4 4 2 2 2 2 2 Today, screen printing and ink jet are the two most common printing processes. For future high volume needs, the other R2R will become more important. Screen printing is suitable for 1 1 1 3 both low volume and high volume. 1 3 3 2 Why did you miss out inkjet printing??? 2 3 2 3 1 1 1 1 1 2 2 1 Processes for very fine scales increasingly 1 2 2 1 important - ie below 25um 4 4 4 4 3 3 3 3 3 3 1 2

DIGITAL PRINTING WILL ALSO BE ESSENTIAL 3 1 1 4 AS WELL AS VACUUM DEPOSITION 1 1 1 4 1 1 1 4 0 0 0 4 2 2 0 1 1 1 1 1 2 4 4 4 2 2 2 2 Table B.2: Section3 Question1

33 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important are the following sciences in Printed Electronics? Inorganic Organic Material Electricit Electrical Chemistry Chemistry Science y Engineering Additional Comments 4 4 4 1 2 4 4 4 3 3 3 3 4 1 4 2 1 2 0 2 1 4 3 0 0 Why did you miss out physics???? 3 3 3 1 1 1 1 1 3 3 4 2 4 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 3 3 2 ELECTRONICS AS A STAND 1 2 3 2 2 ALONE DISIPLINE 1 1 2 2 1 1 1 2 3 2 2 3 3 3 4 2 3 4 1 2 3 3 4 1 3 3 4 4 3 3 2 3 4 2 1 Table B.3: Section3 Question2

34 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important is an understanding of the following software in Printed Electronics? Graphic Business Database VDP CAD Design Applications Software Software Software Additional Comments 2 2 0 0 1 1 0 0 1 4 1 1 1 1 1 3 0 2 0 0 2 3 3 2 2 3 2 2 0 0 3 2 2 0 0 1 I don’t think this is a key issue at the moment - maybe it will become one as the industry 1 1 1 1 1 matures 1 3 1 1 4 2 3 2 2 2 2 4 2 2 4

MORE IMPORTANT WOULD BE ELECTRONIC CIRCUIT SOFTWARE. i DON’T KNOW IF ANY 2 2 2 2 2 OF THE ABOVE INCLUDE THIS. 1 1 1 1 2 4 3 3 1 4 4 3 3 1 4 2 3 3 1 1 0 0 0 0 0 2 1 3 0 3 I am guessing in VDP since I don’t know it The software expertise depends on the job 2 2 3 2 1 function Table B.4: Section3 Question3

35 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important is an understanding of the following materials in Printed Electronics? Inks & Coatings Substrates Laminates Adhesives Additional Comments 3 3 3 3 4 4 3 3 3 3 1 1 4 4 2 3 4 2 3 2 3 3 2 3 2 2 2 2 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 1 1 4 3 2 3 3 3 2 2 3 3 2 3 4 4 4 4 4 3 3 3 1 2 1 1 3 4 4 4 4 4 4 3 Table B.5: Section3 Question4

36 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important are the following skills in Printed Electronics? Identifying Reading Electronic Tracing Programming Schematics Components circuitry computer chips Additional Comments 0 1 1 0 3 3 3 1 1 2 1 0

1 1 3 2 1 1 2 2 1 1 1 1 0 0 0 0 2 2 2 0 3 3 3 3 1 2 1 1 0 ELECTRONIC TESTING 3 3 4 1 CAPABILITY IS ALSO ESSENTIAL Programming computer chips will usually fall in the contract manufacuring area where an IC component is soldered to a pcb and provides instructions for the 2 2 2 0 design. 4 3 4 0 4 4 4 3 3 1 0 0 1 2 2 2 1 2 2 0 2 1 2 1 Table B.6: Section3 Question5

37 Ratings for this question are:

0 Not Important : 1 Somewhat Important : 2 Important : 3 Very Important : 4 Essential

How important is a knowledge of a programming language in Printed Electronics? (please list most important languages) Importance Programming Languages 1 0 0

2 N/A 1 1 1 2 1 4 I WOULD’NT KNOW

Being able to write programs for IC’s is a useful tool, but not one that I would think relates to printing 0 electronics. (membrane switches, EL panels etc.) 0 2 0 0 2 1 Table B.7: Section3 Question6

38

What educational components would you look for from a student in graphic communications entering into the printed electronics industry? Knowledge of printing techniques, their advantages, limitations, practical, how-to-use knowledge 1) Understanding of the history of printed electronics - which goes back >30 years when considering MTS (Membrane Touch Switch); and >40 years when considering printed conductors on ceramic substrates that make hybrid microcircuits. 2) Understanding of the differing opinions on what is Printed Electronics. For example, it could be as simple as MTS, or as complex as printed transistors with printed organic semiconductors. 3) Base understanding of the different options and trade-offs of substrates (PET, PEN, PI, PC, Paper, etc.) conductive materials (Ag, Cu, Au, C - nano vs. non-nano) comparing cost, performance, reliability, and ultimate disposal issues. a feel for how the materials he is working with interact with electrical and materials needs A STRONG SCIENCE BACKGROUND IN PHYSICS, CHEMISTRY AND ELECTRONICS.

Proficient use of graphic design software and a very strong understanding of color separations. Classes should cover inks, plastics, color theory, simulated process printing, and icc profiling. Basic electronics, computer literacy, able to read and understand drawings, CAD knowledge of consumer goods and packaging

They should have gotten a basic background in the chemistry, physics and materials science relevant to the industry. While they would not need detailed electronics knowledge (there would be other team members for that) they should have learned about some of the basic devices and the special problems in printing them and circuits made from them. good understanding of the needs in the flexible electronics industry Table B.8: Section4 Question1

What kinds of class projects would you expect a student in graphic communications to have worked on prior to entering into the printed electronics industry? Printed conductive traces; printed EL lamps; printed OLED devices; printed transistors Read Innovator’s Dilemna, and design a disruptive application involving PE.

Made some simple circuits to give basic ideas - eg screen printing of conductors, making simple devices, anything that provides context. Also work on degradation of properties over time and designs that overcome this. DRAWING TO SUBSTRATE REPRODUCTION ACCURACY. CONTROLLING INK THICKNESS

Students should be able to set up a color management system to synchronize two or more presses. Students should also be able to follow directions from an engineering print to make art files and output films. Graphic layout, typography, color theory, imposition, managment, estimating, MS Excel and Word, CAD functional packaging design Either some kind of integration of a functional electronic unit (e.g. label) ,which might be provided externally, into a graphics or packaging format, or some project on printing some functional materials for electronics, preferably including some devices. printed circuits, assembly of a device Table B.9: Section4 Question2

39

What kinds of research would you expect a student in graphic communications to have participated in prior to entering into the printed electronics industry? Materials, New printing techniques that allow structures below 10 microns. Materials science Some kind of hands-on lab experimentation with basic circuits and substrates.

Understanding of what line spaces are required - fine dimensions in general, degradation of materials. What is soluble and what is not in solvents, how to get good lived suspensions for inks. INK CONDUCTIVITY, CAPACITANCE, MIGRATION, VOLUME AND SURFACE RESISTANCE. VARIABLES AFFECTING ABOVE Color profiling, printed circuitry. Practical electronic application, Graphc design to print project, creative design for packaging A more detailed version of the above. this can vary Table B.10: Section4 Question3

What organizations would you expect a student in graphic communications to be a member of, or become a member of, when entering into the printed electronics industry? Open-Ended Response There is not a need for person to be a member of an organization. Some experience in the field or related field is more valued. Organization involvement will evolve. MRS IEEE would be a possible. Any electronics based organizations to demonstrate a true interest in the field. Maybe join IEEE or an electronics part of a materials organization. IEEE, IPC, ANYTHING INVOLVING ELECTRONIC TESTING AND MEASUREMENT None. Screen Printing and Graphic Imaging Association. Consumer Electronics Association. FlexTech Alliance Table B.11: Section4 Question4

40

How would you describe the printed electronics industry to students graduating with a degree in graphic communications? Open-Ended Response

Extension of traditional printing technologies into new, potentially large application fields with opportunities in R&D, business development and management, both in startups and established companies

There has been a lot of recent activity (and hype) regarding PE. There appears to be a pending convergence of the PE and graphics printing industries. As "Killer Apps" are identified, PE may be seen as a classic Disruptive Technology. Where things are happening. A growing industry segment.

New, small, great potential, growth pains to come, problems to come, problems to solve, huge needs, cost driven, properties driven PRINTED ELECTRONICS IS MORE DEMANDING, MORE TECHNICAL, MORE DYNAMIC

Extremely precise. This industry does not have the automation that you find in the other printing industries. Every job is custom and has to be approached accordingly. `

The printed electronics industry inculdes Membrane switches, Pritned Circuits Boards. They have similar processes as wella s differentones. An exmaple would both can be silk screened but in the caes fo PCBs they go thrrugh an etching process where as memebrane switches do not.

ways to add functionality to everyday printed media such as lighting, moving pictures, sounds, vibrations, communication with handheld devices such as cell phones

A very diverse but also still nascent industry, which brings together technology from physics, chemistry, printing, electronics, system integration, materials science and packaging to develop new products and add functionality to everyday objects.

An indistry that takes the basics in Graphic Arts and extends them to adjacent market ares. This requires an appreciation for understanding new and yet explored areas married with a solid understanding of classic printing concepts. Table B.12: Section4 Question5

41

Where do you see the printed electronics industry in 5, 10, 20 years? (growth, technologies, importance, etc.) Open-Ended Response printed electronics industry will become very importatn but still believe ti will suppot lower end of consumer electroncis. Dependint most on material develment rather then art of printing. Ink jet printing should not be ignored Widespread recognition, preferred technology and established in niche markets, growing rapidly There is a lot published here by Market Research firms. See above. Mainstream manufacturing processes for some claasses of display and possibly lighting. Continued growth. Both low end (cheap throwaway products, and high end (large wrap around the wall screens).

5 - 10 % ANNUAL GROWTH IN 5 YEARS. mORE IN 10 YEARS. PRINTE ELECTRONICS - ESPECIALLY DIGITAL WILL BE INSTRUMENTAL IN THE DEVELOPMENT OF COST EFFECTIVE PHOTO VOLTAIC AND BATTERY TECHNOLOGY. This is a very slow industry. I think that the major change(s) will come from inkjet. My belief is that the industry will become more reliant on eviromentally safe processes. It will grow and expand as the world becomes more dependent on electronic devices. Employees will need to be more educated as technology increases.

5 years - smart packaging, printed sensors e.g. wound management 10 years - printed RFID 20 years - distributed electronics integrated with Si electronics, e.g. smart systems (fridges that can tell you what has been removed and to buy some more, etc)

I think we will see a decision point in the next few years. If first market penetration is successfully achieved by a few companies and the long predicted but delayed market growth set in, the industry will continue to diversify and grow rapidly over the next 20 years. If not then the future is perilous. It is expected that early generation products with simple functions will hit the market over the next 5 years, with more sophisticated products (e.g. integrated sensor systems with power supply, sensor, display and control circuitry all on board) coming in the following 5 years. After that it’s anyone’s guess what creative developers will come up with.

It will grow considerably but I am unable to suggest growth numbers. I beleive it will be a major player in the overall electronics market. Table B.13: Section4 Question6

42 Appendix C

Scores from Student Examination

Table C.1: Exam Results

43 Appendix D

Student Examination

Figure D.1: Exam Page 1

44

D.2: Exam Page 2

45 Figure D.3: Exam Page 3

46 REFERENCES

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