Electronics Sensors on 3D Surfaces
Business challenge
Sustainability & Net Zero
Process Innovation
Sector
Electrification
Technology or capability
Additive Manufacturing
Unlocking New Possibilities for Smart, Connected 3D Structures
Advances in additive manufacturing and the rapid emergence of new 3D printing systems are transforming how engineers design and integrate electronics.
This project explored the capability to print electronic sensors directly onto 3D surfaces, whether embedded within or applied to metal and polymer structures, to support the next generation of smart, connected industrial assets and drive future IoT innovation.
Project Challenges
- Assess the current additive electronics landscape, including equipment, design principles, processing techniques and emerging ink technologies.
- Understand how surface preparation on metals and polymers influences adhesion and electrical performance of printed sensors.
- Develop and print basic strain gauges and antennas directly onto 3D geometries.
- Define environmental validation methods to ensure the long-term reliability of printed electronics in industrial environments.
MTC's Solution
- Conducted an in‑depth literature and market review to identify leading additive electronics technologies, design methodologies and software platforms.
- Selected three key metals: copper, steel and aluminium, and used laser ablation to generate controlled surface textures. Dielectric layers of varying thicknesses were printed, followed by conductive tracks, to assess electrical behaviour and optimise adhesion.
- Designed, printed and tested strain gauge sensors on complex 3D geometries to explore functional performance.
- Reviewed industry standards for environmental testing of 3D‑printed electronics and produced costed recommendations to support informed investment decisions.
Structural, printed electronics offers huge potential for low-cost, connectivity and condition monitoring of every-day devices. The ability to print strain gauges and antenna directly onto conductive surfaces shows that AME is moving closer to widespread adoption.
Dr Mickey Crozier, Chief Engineer - MTC
The Outcome
- Delivered a practical toolset to support technology selection and assess the viability of different additive processes for future product applications.
- Demonstrated how laser texturing can enhance surface adhesion and increase confidence in process reliability.
- Provided a comprehensive review of environmental testing equipment and service providers, enabling clients to choose suitable options for their intended test conditions.
- Produced a detailed report covering additive manufacturing electronics (AME) for 3D surfaces, including equipment, process chains and design rules.
- Developed a defined process flow for AME on 3D objects and a curated list of suitable equipment providers for printing, post‑processing and materials.
Benefits to the Client
- Increased understanding of how additive electronics techniques can be applied to create 3D sensors and smart surface functionality.
- Clear insights into surface preparation methods, supported by laser texturing demonstrations showing improvements in adhesion performance.
- Independent guidance on environmental test equipment and providers to support confident procurement decisions.
- Access to material reviews covering conductive and dielectric inks to streamline future development pathways and supply‑chain planning.
