Development and Applications of Overmolded Smart Components

PROJECT COST:

975 000 $

PRIMA CONTRIBUTION:

195 000 $

PROJECT DETAILS:

Smart Parts are defined as parts, structures, and/or assemblies that incorporate a smart function directly embedded in the structure in the form of hardware and/or software (e.g., sensors and actuators). The integrated manufacturing of these parts—produced by overmolding pre-thermoformed printed electronic components—is considered a revolutionary technology that will transform traditional methods of manufacturing electrical parts, which date back more than a century. This new approach (printed circuit boards, thermoforming, and overmolding) will transform the industry by enabling advanced electrical integration (backlighting, touch controls, etc.), leading to ultra-lightweight, ultra-thin, and less expensive smart parts. By combining the exceptional formability of printed electronic structures—made possible by the NRC’s patented conductive molecular inks—with overmolding technologies for thermosetting (patent pending) and thermoplastic resins, it will be possible to clearly demonstrate all the benefits of this new technology in order to create a new field of applications within this emerging industry.

The project aims to address the knowledge gap regarding the formability of molecular inks, to develop overmolding processes for electrical applications, and to push the boundaries of these processes. At the end of the project, a prototype part will be co-developed and manufactured by the partners to demonstrate the robustness of the concept. The synergy between (1) the deformability of the new conductive molecular inks and (2) the versatility of reaction injection molding (RIM) and thermoplastic injection molding processes will make it possible to expand the scope of the manufacturing process for smart parts to include the production of highly complex parts.