In-mold electronics (IME) can allow for surfaces or 3D structures to become functional, with embedded electrical components, to streamline and increase performance capabilities.

IDTechEx’s report, “In-Mold Electronics 2025-2035: Forecasts, Technologies, Markets,” covers some of the main application areas for IME and its manufacturing processes, along with predictions for its uptake over the next decade.

The Capabilities of IME and the Growing Market

Aesthetics and practicality can be combined with in-mold electronics technology in a unique and modern way. Structural electronics has been seeing numerous trends of miniaturization and lightweighting, along with new shapes, designs, and fast customization possibilities. IDTechEx forecasts the IME market to hit US$974 million by 2035, showcasing its scope for success.

Capacitive switches and lighting are amongst the most common examples of IME to date. The automotive sector, however, has recently been a large driving force behind the development of IME technologies, to create streamlined interiors, such as with dashboard switches. IDTechEx also reports that other applications such as wearable and consumer medical devices and certain appliances will also create opportunities for IME.

Commercial Advantages and Reducing Materials

IDTechEx lists some of the commercial advantages to in-mold electronics. Aside from their light weight and streamlined aesthetic, they will also need to be subject to durability and quality requirements as a result of strict automotive regulations and their presence within this market. IME also includes the benefit of design versatility, as well as being appropriate for high-volume production, which as a result can achieve economies of scale and lowered costs.

With the development of in-mold electronics, printed circuit boards (PCBs) are no longer necessary, as instead, components can be applied directly onto surfaces. Conductive ink and adhesive technologies can be used in the screen-printing process of IME, while polycarbonate materials are used as substrates.

These can subsequently be molded into a 3D shape by thermoforming, and lastly injection moulding. IDTechEx’s report, “Conductive Inks Market 2024-2034: Technologies, Applications, Players,” and the printed and flexible electronics portfolio provides greater depth into these materials.

The subsequent reduction in plastic and individual components achievable with IME not only results in positive environmental impact, but in reduced overall costs and the possibility for sleeker designs.

The Benefits and Drawbacks of IME with SMD

The process of placing surface mount devices (SMDs) onto a thermoformable plastic film using conductive adhesive can be an alternative to the method of printing conductive traces directly onto the film, using screen printing.

IDTechEx reports that IME with SMD can provide increased functionality compared to other methods, as LEDs and sensors can be integrated with this method, meaning the possibility to include electronics into a variety of form factors could also be enabled.

Other notable benefits include quicker manufacturing times than with alternatives, and reduced assembly costs. IME without SMD is also currently limited to applications like capacitive touch sensing or antennas, meaning it likely does not have the same scope for innovation, presenting the SMD method as more versatile.

However, SMD areas on a structure are required to stay flat in order to maintain optimal performance, which could potentially bring about limitations, while the thermoformable substrates and inks required for the process are also costly.

IDTechEx also reports the need for high yields and accuracy to avoid wasting materials, as once molding is complete and the parts are integrated, there isn’t much room for tweaking.

IDTechEx reports that the coming years will determine much of the success of IME, and whether the forecasted amount will come to fruition, with the potential for a large increase in revenue in line with automotive adoption.

IME manufacturing could also be integrated into existing processes within industries, according to IDTechEx, meaning the barriers to adoption have the potential to be relatively low, should the demand be high enough to warrant its growth.