Injection Molded Electronics:

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Domenic Booker
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1 Injection Molded Electronics: Mass Manufactured Smart Plastics Dr. Antti Keränen CTO, Co-Founder TactoTek Oy

2 TactoTek IMSE building blocks IMSE Injection Molded Structural Electronics Printed electronics Chip-based electronics Injection molded structures TactoTek

TactoTek Process Flow Overview Integrate printed

inside of plastics Manufacturing flow 1.

Print wiring, touch controls, and antennas 3.

3 TactoTek Process Flow Overview Integrate printed circuitry and traditional electronic components inside of plastics Manufacturing flow 1. Print decoration 2. Print wiring, touch controls, and antennas 3. Mount components on flat film 4. Pre-form 5. In-mold smart insert Smart In-Mold Labeling (IML) TactoTek

4 Representative Use Cases Illumination & styling TactoTek LightStripe 3D HMI surfaces TactoTek ControlSurface Thin flexible wearables & Soft sensor components Rigid and flexible designs: wide range of molding materials including PC, ABS, PMMA, and TPU Encapsulated circuitry and electronics deliver design freedom and durability TactoTek

and wiring harness IMSE is perfect platform for integrating Printed Intelligence into devices

5 Printed Electronics in IMSE Touch controls capacitive 1D buttons, 2D sliders, 3D gesture control Antennas printed NFC, Bluetooth/WLAN Proximity sensing Circuitry flexible circuitry and wiring harness IMSE is perfect platform for integrating Printed Intelligence into devices Printed elements within surface structure, not buried to separate electronics board TactoTek

Traditional Electronics in IMSE Electronic Components

BLE (bluetooth low energy), LED drivers etc.

need for expensive customization Pin-to-film connections

6 Traditional Electronics in IMSE Electronic Components Illumination single/multi-color indicators, ambient lighting, logo/branding, animate Sensors accelerometer, stress, impact, etc. Integrated circuits (ICs) MCUs (microcontroller units), BLE (bluetooth low energy), LED drivers etc. In-mold circuit boards (PCB, FPC) Off-the-shelf components No need for expensive customization Pin-to-film connections withstand thermoforming and injection molding Rigid components on flexible parts TactoTek

Innovation Example: In-Mold Lighting Structure as

added light-guides/light pipes Indicators, logos, dynamic

Side view: Top view: Clear Plastic TactoTek 2016 7

even illumination, new lighting designs Manufacturing:

7 Innovation Example: In-Mold Lighting Structure as light-guide (TactoTek patented) Very thin: down to <1mm No added light-guides/light pipes Indicators, logos, dynamic deco etc. Side view: Top view: Clear Plastic TactoTek Illuminated area LED(s) Design: Thin, light, 3D, bright and even illumination, new lighting designs Manufacturing: Simple assembly single functional element with LEDs and circuits Durability/Protection: Circuitry and electronics encapsulated in molded plastic

IMSE Example: Fully Integrated Control Panel TactoTek ControlSurface Demonstrator 1 5 2 3

LightStripe 4) Proximity sensing cover 5) Hidden-until-lit icons 6) Recessed capacitive slider

8 IMSE Example: Fully Integrated Control Panel TactoTek ControlSurface Demonstrator Electronics film structure ) Recessed capacitive buttons 2) NFC 3) TactoTek LightStripe 4) Proximity sensing cover 5) Hidden-until-lit icons 6) Recessed capacitive slider 7) Printed graphics & effects 8) 3 mm injection-molded plastic 9) In-mold system electronics TactoTek

TactoTek Benefits Light weight Reduces weight 50-70%

feature/function possibilities Durable and reliable

debris Scalable mass production Standard equipment and

assembly depth Simple assembly 30% savings from fewer

Easy model-specific versioning; single component

9 TactoTek Benefits Light weight Reduces weight 50-70% Fewer parts, less plastic used Design freedom New feature/function possibilities Durable and reliable Shock and impact resistant, protected from moisture and debris Scalable mass production Standard equipment and known materials TCO Space efficient Up to 90% less assembly depth Simple assembly 30% savings from fewer parts and electrical connections Fast product updates Easy model-specific versioning; single component customization Faster to service Single part replacement reduces time up to 40% TactoTek

10 Selected Automotive IMSE Application Areas MULTI-FUNCTION HEADLINER MULTI-FUNCTION SEATBACKS SMART B-PILLAR e.g. KEYLESS ENTRY SMART STEERING WHEEL MULTI-FUNCTION OVERHEAD CONTROL PANELS ILLUMINATED VENTILATION TRIM PANELS AND CONTROLS SMART TAILGATES AND LIGHTING SOFT FABRIC SENSING e.g. SEAT SENSORS CURVED & FLUSH DESIGNED SMART CENTER CONSOLES Illumination & control solutions in curved decorative panels Force and capacitive sensing integration for enhanced applications, preventing unintentional activations Illumination adjustment TactoTek SMART DOOR HANDLES e.g. KEYLESS ENTRY RE-ARCHITECTED CONTROLS e.g. DOOR CONTROLS RELOCATED INTO DASH PANELS

Printing Surface Mounting Forming Injection Molding Unprecedented inter-disciplinary knowhow from Materials to Molding and between Whole

11 Accelerating Design to Mass Manufacturing Design-to-Product in-house Product design according to progressing Design for Mass Manufacturing design rules Immediate feedback from manufacturing to design and between different steps Holistic process handling Printing Surface Mounting Forming Injection Molding Unprecedented inter-disciplinary knowhow from Materials to Molding and between Whole manufacturing chain in-house PoC and (Pilot) Production ensures design viability Critical data for technology transfer to customer/3rd party TactoTek

Very high High Injection Molding Very high Very high Very high Combined (IMSE) Ready for MP

12 SCALABLE Manufacturing Methods Method Maturity Scalablility Readily Available Capacity Screen printing Very high Very high Very high 2D SMA Very high Very high Very high Forming Very high Very high High Injection Molding Very high Very high Very high Combined (IMSE) Ready for MP High Easily Attainable* *IMSE scaling uses existing equipment NOT unique equipment TactoTek

13 IMSE Environmental Testing Performance TactoTek Internal test example: Tested device: TactoTek ControlSurface TM demonstrator Two film structure All Electronics in-mold PASSES (Cap touch, lighting, VQ) e.g cycling 85 C/85%RH 1000h Customer product tests: Several products under Automotive specific tests Some products for wearable parts approved -40 C to 80 C (96%RH) Cycle 1h 1h 96%RH at 80 C 1h Every IMSE product needs testing, different Geometry Materials Electronics 1h But basic recipes and material combinations are ready for survival TactoTek

Recognized leader in structural electronics Founded in 2011 Core business: manufacturing and technology licensing of 3D smart inmolded electronics Patented and patent pending manufacturing processes

14 Recognized leader in structural electronics Founded in 2011 Core business: manufacturing and technology licensing of 3D smart inmolded electronics Patented and patent pending manufacturing processes and applied uses Design services to migrate traditional designs into structural electronics designs Primary markets: Automotive, IoT, Wearables, Appliances, Medical Devices TactoTek locations Oulu (HQ), Germany, Sweden, Switzerland, USA, China, Taiwan, South Korea, Japan TactoTek

15 Dr. Antti Keränen CTO, Co-Founder TactoTek Oy

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