Joint program achieves near-100% yield across 100+ production units, signaling a new, disruptive production-ready path for printed electronics in aerospace
AUSTIN, TX, UNITED STATES, October 19, 2026 /EINPresswire.com/ — Electroninks, the leader in metal complex inks for additive manufacturing and advanced semiconductor packaging, and Integrated Deposition Solutions (IDS), a developer of aerosol printing systems and process solutions, today announced the results of a joint manufacturing program that slashed production time per device by 73% while achieving near-perfect yield, a milestone that demonstrates aerosol-printed electronics are ready to move from the lab into scaled aerospace production.
Over a three-week qualification run, IDS manufactured more than 100 multilayer printed heaters to strict electrical specifications, a target resistance of 30 ohms within a ±3 ohm tolerance, using a newly created standard operating procedure jointly engineered in cooperation with Electroninks. Every device fell within tolerance, and the companies report manufacturing yield approaching 100%.
“This result is proof of what’s possible when materials science is engineered specifically for manufacturability, not just performance in a lab setting. Our particle-free ink chemistry was built from the ground up to behave predictably at production scale, and that’s exactly what this new proprietary process proves,” stated Mike Torre of Electroninks. “We’re not just supplying ink to the printed electronics industry; we’re redefining what aerospace manufacturers can expect from direct-write processes. This is the kind of innovation that moves printed electronics out of the prototype phase and into mission-critical production faster.”
Printed electronics have long promised lighter, more flexible, more customizable circuitry for aerospace systems, but inconsistent yield and manufacturability have kept many programs stuck in prototyping. This collaboration tackles that gap directly, pairing Electroninks’ particle-free conductive and dielectric materials with IDS’s aerosol platforms to create a workflow precise and repeatable enough for qualification-grade production.
Key technical advances driving the results include:
* A fully on-platform process. Electroninks’ UV-curable polyimide (insulation/encapsulation) and EI-615 silver (conductive layer) were both cured and processed directly on the printing system, eliminating external oven steps and the cycle time and variability they introduce.
* Low-temperature compatibility. EI-615’s low-temperature processing held substrate temperatures to a maximum of 120°C, widening the range of aerospace-grade substrates the process can support.
* A scalable pre-batching methodology. A standardized material pre-batching approach, built into the SOP, simplifies technology transfer from engineering teams to production technicians, addressing a frequent bottleneck when moving printed electronics from R&D to volume manufacturing.
* Major throughput gains. Continued optimization of print paths and production flow drove a 73% reduction in manufacturing time per device over the course of the project.
* A streamlined production platform. The NanoJet Gen2 system combines aerosol deposition with integrated process controls in a platform designed to simplify operation and support repeatable manufacturing workflows.
The qualified devices have now entered environmental testing to verify long-term reliability and technology readiness for aerospace operating conditions.
“This project highlights the value of close collaboration between materials developers and process engineers,” said Dov Phillips, sales manager at Integrated Deposition Solutions. “The performance targets required much more than selecting the right materials. Success depended on developing a complete workflow that could consistently deliver repeatable results day after day, operator after operator.”
Looking ahead, Electroninks and IDS are jointly developing the integration of in-situ laser processing with Electroninks’ particle-free silver inks, enabling conductive features to be cured immediately after deposition. The companies say this could further compress cycle times and extend direct-write manufacturing beyond flat substrates, opening the door to functional electronics printed across large or complex three-dimensional surfaces.
“Together, we’re showing that high-performance materials and precision deposition can deliver the production consistency aerospace programs require,” continued Phillips, pointing to the broader implications for next-generation printed electronics across aerospace and industrial markets.
For additional product specifications and availability information, visit www.electroninks.com.
###
About Electroninks
Electroninks Incorporated is a world-leader in the commercialization of advanced materials for electronics and semiconductor packaging. We have developed a full suite of proprietary metal complex conductive ink solutions and complementary material sets, thus accelerating time to market for both new innovations and drop-in manufacturing breakthroughs.
Electroninks’ metal complex inks – including silver, gold, platinum, nickel and copper – deliver higher conductivity, manufacturing flexibility, and cost-effectiveness. The company’s conductive inks provide reliable solutions for applications in printed circuit board (PCB) manufacturing, semiconductor packaging, consumer electronics, wearables, medical devices and more. We also partner closely with best-in-class equipment and integration partners to provide customers with a total ink and process solution with the ultimate goal of reducing the manufacturing costs and complexity.
To learn more visit: www.Electroninks.com
Contact@Electroninks.com
512-766-7555
About Integrated Deposition Solutions (IDS)
Integrated Deposition Solutions (IDS) is a leading developer of advanced aerosol printing systems and precision deposition solutions for printed electronics, advanced semiconductor packaging, microelectronics, biomedical devices, and industrial manufacturing. The company’s patented NanoJet™ technology enables high-resolution, non-contact deposition of conductive, dielectric, ceramic and polymer materials with exceptional print stability, repeatability and ease of use. Designed for both research and production environments, IDS’ modular aerosol printing platforms include turnkey systems, desktop research tools and OEM-integrated printheads that help customers accelerate product development while enabling scalable manufacturing. Founded in 2013 and headquartered in Albuquerque, New Mexico, IDS serves customers across five continents with technologies that simplify advanced additive manufacturing and precision electronics fabrication. For more information, visit www.idsnm.com
Nicolia Wiles
PRIME|PR
+1 833-279-8096
Visit us on social media:
LinkedIn
Facebook
Legal Disclaimer:
EIN Presswire provides this news content “as is” without warranty of any kind. We do not accept any responsibility or liability
for the accuracy, content, images, videos, licenses, completeness, legality, or reliability of the information contained in this
article. If you have any complaints or copyright issues related to this article, kindly contact the author above.
Media gallery
