MADRAS · Project

Smart Electronics Printed Directly Into Plastic Parts During Manufacturing

manufacturingPilotedTRL 6

Imagine if you could print sensors, antennas, and circuits directly onto plastic parts while they're being molded — no separate electronics assembly needed. MADRAS developed special inks made from silver nanowires and metal oxide nanoparticles that can be screen-printed or spray-coated onto surfaces, then sealed inside injection-molded plastic. Think of it like printing a newspaper, but instead of text, you're printing working electronics that end up embedded in everyday products. They built two demo products: a smart authentication tag and a sensor for factory use.

By the numbers

New high-performance materials developed

Product demonstrators built (authentication + smart manufacturing)

Consortium partners across value chain

SMEs in consortium forming commercial pathway

Countries represented in consortium

64%

Industry partner ratio in consortium

The business problem

What needed solving

Manufacturers today struggle to add electronic functionality (sensors, antennas, touch controls) to plastic products because it requires separate circuit boards, wiring, and assembly — adding cost, weight, and production steps. Current organic printed electronics are too expensive, unstable, and short-lived for industrial use, forcing companies to rely on bulky conventional electronics even when space and weight are critical.

The solution

What was built

MADRAS developed 4 advanced printable materials (silver nanowire inks, metal oxide semiconductor inks, transparent conductive substrates, organic semiconductor inks) and a scalable In Mold Hybrid Printed Electronics (IMHyPE) manufacturing process that prints circuits directly into plastic parts during injection molding. Two product demonstrators were built: a persons' authentication device and a smart manufacturing sensor.

Audience

Who needs this

Automotive Tier 1 suppliers embedding sensors in plastic interior panelsSmart packaging companies producing NFC tags and authentication labelsIndustrial IoT equipment makers integrating sensors into machine housingsConductive ink and specialty materials suppliersContract manufacturers offering printed electronics services

Business applications

Who can put this to work

Automotive

enterprise

Target: Automotive parts manufacturers and Tier 1 suppliers producing interior panels, dashboards, or body components

If you are an automotive parts manufacturer dealing with the cost and weight of adding sensors, touch controls, and antennas to plastic interior components — this project developed In Mold Hybrid Printed Electronics (IMHyPE) that prints conductive inks directly into injection-molded plastic parts. This eliminates separate PCB assembly steps, reduces part weight, and accelerates time-to-market by combining electronics integration with your existing plastic injection process.

Consumer Electronics & Smart Packaging

SME

Target: Producers of smart labels, NFC tags, and authentication devices

If you are a packaging or security company struggling with the high cost and short lifetime of printed electronic tags for product authentication — this project developed 4 high-performance materials including transparent conductive inks and semiconductor inks that are more stable and cheaper than current alternatives. The 2 demo products include a persons' authentication device that could replace expensive chip-based solutions with printed electronics at scale.

Industrial IoT & Smart Manufacturing

mid-size

Target: Factory equipment manufacturers integrating sensors into production environments

If you are an equipment manufacturer looking to embed sensors directly into machine housings or production line components — this project built a smart manufacturing demonstrator using printed photosensors and antennas on flexible plastic substrates. With 14 consortium partners including 6 SMEs already in the value chain, the manufacturing methodology is designed for high-throughput, scalable production using screen printing and spray coating.

Frequently asked

Quick answers

What would it cost to adopt this printed electronics technology?

The project data does not include specific pricing. However, the core value proposition is cost reduction — IMHyPE replaces separate electronics assembly by printing circuits during plastic injection molding, eliminating component costs and assembly labor. The use of spray coating and screen printing on existing plastic injection lines suggests integration with standard manufacturing equipment.

Can this scale to industrial production volumes?

Yes, this was designed for scale from the start. The manufacturing methodology builds on established plastic injection molding — already a high-throughput industrial process. The project specifically targeted high-speed manufacturing with high throughput capabilities, and the Innovation Action funding scheme required demonstration at near-industrial scale.

What is the IP situation and how can I license this technology?

The consortium of 14 partners across 5 countries likely generated IP around the 4 advanced materials (silver nanowire inks, metal oxide semiconductor inks, transparent conductive substrates, organic semiconductor inks) and the IMHyPE manufacturing process. Licensing would need to be negotiated with the coordinator FUNDACIO EURECAT in Spain or relevant consortium partners.

How mature is this technology — is it ready for my production line?

As a completed Innovation Action (2020-2023), MADRAS demonstrated working prototypes of 2 products: an authentication device and a smart manufacturing sensor. The technology has been validated in relevant environments but would likely need engineering adaptation for your specific production requirements. Estimated technology readiness is TRL 6.

What materials were actually developed?

MADRAS developed 4 high-performance materials: a conductive and transparent substrate, a semiconducting transparent ink based on organic components, a transparent conductive silver nanowire-based ink, and a semiconductor ink based on metal oxide nanoparticles. These address the cost, instability, and short lifetime problems of current organic electronics.

Which industries can use this beyond automotive?

The project identifies automotive, healthcare, and consumer products as large addressable markets for structural electronics. The 2 demonstration products target persons' authentication and smart manufacturing, but the underlying printed electronics platform applies wherever you need lightweight, embedded sensors or connectivity in plastic parts.

Consortium

Who built it

The MADRAS consortium is strongly industry-oriented with 9 out of 14 partners from industry (64%), including 6 SMEs — a clear signal that this was built to reach the market, not stay in the lab. Coordinated by FUNDACIO EURECAT, a major Spanish technology center, the project spans 5 countries (Czech Republic, Denmark, Spain, France, Netherlands) covering Western European manufacturing hubs. With only 1 university partner versus 3 research organizations and 9 industry players, the consortium was structured as a complete value chain from materials development through manufacturing to end-product integration. For a business looking to adopt this technology, the strong SME presence means there are likely commercial partners ready to supply materials or manufacturing services.

FUNDACIO EURECATCoordinator · ES
UNIVERZITA PARDUBICEparticipant · CZ
ASOCIACION ESPANOLA DE NORMALIZACIONparticipant · ES
GENES'INKparticipant · FR
ETICAS RESEARCH AND CONSULTING SLparticipant · ES
NEDERLANDSE ORGANISATIE VOOR TOEGEPAST NATUURWETENSCHAPPELIJK ONDERZOEK TNOparticipant · NL
CENTRUM ORGANICKE CHEMIE SROparticipant · CZ
ARJOWIGGINS FRANCEparticipant · FR
F1 PAPERSparticipant · FR
INFINITYPV APSparticipant · DK
NUEVAS TECNOLOGIAS PARA EL DESARROLLO DE PACKAGING Y PRODUCTOS AGROALIMENTARIOS CON COMPONENTE PLASTICA SLparticipant · ES

How to reach the team

FUNDACIO EURECAT is a technology center based in Spain — contact their printed electronics or advanced manufacturing division.

Order a report on this consortium See FUNDACIO EURECAT profile →

Next steps

Talk to the team behind this work.

Want to connect with the MADRAS team for licensing, materials supply, or manufacturing integration? SciTransfer can arrange a direct introduction to the right consortium partner for your needs.

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