The Benefits of Direct-Write Technologies to Enable FHE Onto Real Systems and Structures

In the past, the ability to Direct Write Flexible Hybrid Electronics (FHEs) onto existing structures was severely limited in scale which restricted the process to small parts or prototype demonstrators. The development of the Large Gantry Direct Write Printing System has changed the conversation and the possibilities. SI2 and NextFlex are maturing the capability and the capacity to Direct Write FHE onto large pre-existing structures like aircraft wings, radomes, and simple structural panels using new in-house gantry systems. With a print volume of over 100 cubic feet—yet maintaining a dynamic accuracy within a thousandth of an inch—these gantry systems are capable of scanning, mapping, and printing onto structures too large to fit within most Direct Write systems. Using the latest laser scanning and point cloud mapping technology, we can reverse engineer the actual part geometry, import it into a CAD environment, apply the desired FHE features, and export those features as a CNC toolpath. With a quick change of the payload system, the gantry can then Direct Write functional inks and pastes onto structures and even dry and sinter the printed geometry in-situ using pulsed-UV. This technology holds enormous potential for both DOD and commercial applications that are constrained for size, weight, and power (SWaP). In addition, significant cost savings exist by printing FHE directly onto the existing structure’s surface. The numerous I/O capacity and tightly controlled movement of the Large Gantry Direct Write Printing System offer significant potential for added functionality in the future. SI2’s Mike Borrelli will discuss the evolution of FHE Direct Writing, why harnessing the power of this new technology is making a difference in the way SI2 designs and creates products for the DOD, and the future possibilities that both SI2 and NextFlex are excited to share as the applications are practically limitless.