A unique process for manufacturing flexible hybrid electronics in roll-to-roll compatible fashion at low temperature ( < 100 C), and without the use of solder, polyimide, or etched copper, is outlined. We cover design workflow, production methods, performance validation, and applications. A design workflow for such circuits was adapted from traditional electronic CAD to accommodate the unique architecture of this manufacturing process. Roll-to-roll compatible web processing methods to produce conductive traces, attach components, make electrical connections, and encapsulate are discussed. Conductive traces and electrical connections are made with laser processing and silver ink, components are attached with pressure-sensitive adhesive, and encapsulation is with room-temperature fast-cure silicone. Performance validation results are discussed for an exemplary Bluetooth Low Energy device, along with discussion of the main performance tradeoffs of such circuits. The approach presented is suitable for high-volume production of low-complexity, low-power electronics in a soft, conformable format, particularly for on-skin devices.
