The HyPerStripes Penta-Euripides² project tackled an important challenge in the electronics industry: how to manufacture large-scale, stretchable and flexible printed circuit boards (PCBs) in a cost-effective and sustainable way. Traditional sheet-to-sheet (S2S) processes for producing flexible electronics are limited in size and scalability. HyPerStripes aimed to overcome these constraints by developing innovative roll-to-roll (R2R) manufacturing technologies and tailored assembly methods.
Main Technological Advances
Two novel R2R processes were developed:
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A screen printing-based process on flexible polymer substrates.
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A digital lithography process for stretchable substrates with copper traces.
Custom assembly technologies were designed to support these new production formats:
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Pixel soldering, which enables precise, local heating for component attachment.
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NanoWiring, a Velcro-like connector technology using fine metallic needles, adapted for R2R use.
Together, these innovations allow for the continuous production and functional assembly of extra-long, flexible PCBs, significantly expanding their potential applications.
Application Demonstrators
To validate the new technologies, five advanced demonstrators were developed across the medical and industrial sectors:
• Philips: Smart catheter wiring using twisted flexible PCBs to replace traditional cables.
• Salvia: Flexible neurostimulation implants for migraine treatment.
• OSYPKA: Active implant system with integrated electrode array and signal digitization.
• Signify: Transparent, LED-integrated strips for lighting windows that switch between clear and illuminated states.
• Capical: Intelligent textile bed sheets for continuous health monitoring.
These use cases showcase the versatility and performance of HyPerStripes technologies in real-world environments.
Environmental & Societal Impact
HyPerStripes embraced sustainable design principles throughout development. Life Cycle Assessments of the demonstrators demonstrated significant benefits: up to 65% emissions reduction in lighting demonstrators, over 90% reduction in emissions in some assembly processes.
The project also implemented circular economy principles, including end-of-life strategies and material efficiency.
Dissemination and Exploitation
The project generated valuable intellectual property, notably around the application of NanoWiring in R2R. Dissemination included: 2 webinars, 11 conference presentations, a peer-reviewed publication, 8 trade fair exhibitions. Public release of a design simulation toolchain is available here.
What’s Next?
Building on HyPerStripes’ success, the consortium is preparing a follow-up initiative, MultiStripes project, under the 2024 Xecs Call. The aim is to further industrialise the developed technologies and expand their market readiness across healthcare, lighting, consumer electronics, automotive and more. HyPerStripes stands as a strong example of how collaborative European R&D can address technological bottlenecks, foster sustainability, and strengthen Europe’s industrial competitiveness in advanced electronics.
Discover more in the Project Impact Summary and on the project website.