ELECTRICAL & ELECTRONIC COMPONENTS FEATURE
3D-MID: AN alternative to PCBs? 3
D-MID – injection-moulded plastic parts with conductive traces created
using laser direct structuring (LDS) – is adding power to the trend towards miniaturisation within the electronics industry while also providing product developers with new design opportunities. Johannes Schmid, managing director
of Multiple Dimensions, explains that the basis of all 3D-MID applications is a thermoplastic material. He said: “Using injection moulding, we first manufacture the part to fit the customer’s application. We use different types of thermoplastic which contain an additive that can be activated by laser.” Schmid goes on to explain that a laser ray engraves the surface of the plastic and activates the additive. This is followed by a copper bath which lets the conductive traces form directly on the thermoplastic. Depending on the type of application, the MID parts may have to be extremely robust or temperature- resistant. They may, for instance, need to be acid- or sweat-resistant if used in hearing aids or headphones. Following this, a barrier layer of nickel is applied and then conditioned with a thin layer of gold to ensure good solderability. The company is able to produce traces in almost microscopically small dimensions. According to Schmid, while most suppliers are currently working with 300 to 400µm spacing between traces, at Multiple Dimensions the technological limit for trace width is 80µm. The trace width and spacing between
the traces is the main factor affecting the degree of miniaturisation, and it is decisive in terms of the number of functions that can be integrated in a component.
THE APPLICATIONS Many applications are already using the technology. The fine structures are, for instance, often used in Point of Sales (PoS) terminals as protection from hacking as they allow attacks on the data in the payment cards to be detected. In another example, the rotary switches that are used for programme selection on washing machines are normally made using a range of small mechanical parts. Using 3D-MID technology, none of these are now needed. The washing programme is selected using a capacitive switch therefore is virtually touch-free. Unlike a mechanical solution, there is no friction to wear out the parts. “Our operator control
More and more industry sectors are moving towards 3D-MID (Moulded
device has a much simpler design, costs less to produce and, on top of that, it has a longer service life,” said Schmid. The company also manufactures sensors for the automotive industry which are used to measure the torque and position of steering wheels. Schmid explains that, depending on the position and the measured value, the drive of the power
Interconnect Devices or Mechatronic Integrated Devices) as an alternative to classic PCBs. But what are these and where can they be used? Multiple Dimensions of Switzerland explains
3D-MID could be beneficial for products such as smoke detectors
with conductive traces. The surface of the robot’s tactile organ is covered with sensors, and their pressure signals are routed centrally to a connector. “Thanks to our 3D technology, we can place the required electronics accurately in spite of the complexity of working with a curved surface,” Schmid explained.
THE FUTURE At Multiple Dimensions, all production steps are fully automated and performed in-house. This covers the complete process chain – from injection-moulding to laser processing and galvanisation, and even as far as populating the electronic components. Schmid concludes: “Advances in
steering is increased or decreased. The more accurate the measurement, then the more directly the vehicle response is felt. Again, the conventional solution contains numerous mechanical parts. When all these parts work together, deviations and tolerances cumulate and can impair the driving experience. Schmid added that the technology not only saves components and costs, it also makes the application more precise and efficient. In addition, the technology has been
used by a toy manufacturer. Here, an electronic circuit has been built into a tiny space in a plastic component – including a battery, a capacitive switch and an LED. There would not have been enough space there for a PCB. Smoke detectors could also benefit from 3D-MID. With these, the enclosures are plastic and the conducting traces can be applied directly. It is then possible for the cables, connector plugs and battery holder to be integrated into the moulded part. So, during the production process, complex soldering processes can be eliminated and the assembly simplified due to a small number of parts. It would also be possible for additional functions to be integrated – a capacitive switch could, for example, be used instead of a mechanical one. In the future, the technology will also be used in human-like robots. Experts from Multiple Dimensions are already equipping the fingertips of a robotic hand
miniaturisation which are being made in all areas of our industrial society, combined with the trend for intelligent connectors for Industry 4.0, ensure that 3D-MID technology will be used even more widely in the future.”
Multiple Dimensions
www.multipledim.com
SWITCHING TO BRAKING SYSTEMS
Capable of 0-100mph in just 3.8 sec, Ariel Motor Co’s two-seater HIPERCAR (HIgh PERformance CARbon Reduction) four-wheel drive electric vehicle will be launched in 2020. This will produce 9,900Nm torque through four separate electric motors powered from a 42kWh liquid cooled battery. Herga Technology’s 6721 series vacuum switches have been specified for the car’s servo braking system. These high reliability switches are well proven as part of electric brake pump systems for electric cars and high performance fuelled engines that do not produce sufficient vacuum for optimal servo operation. The 6721 series
vacuum switch is used in many industrial applications. With a vacuum range up to 670mbar, single and double pole switching versions are available with AC and DC connection for resistive, inductive and motor loads. The durable series has a thermoplastic housing and a -5˚C to + 70˚C temperature range, with a typical electrical switching life of up to 2 x 106 cycles.
Herga Technology
www.herga.com
DESIGN SOLUTIONS | JULY/AUGUST 2018
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