TINKER · Project

Faster, Smaller Sensor Packaging for Automotive RADAR and LIDAR via Additive Manufacturing

manufacturingPilotedTRL 7

Self-driving cars need tiny radar and lidar sensors to see the road, but right now those sensors are too bulky to fit neatly into bumpers or headlamps. TINKER built a new production line that uses 3D-printing-style techniques — inkjet printing, nano-imprinting, and smart pick-and-place robots — to assemble these sensors faster and more precisely. Think of it like going from hand-soldering circuit boards to a fully automated factory floor. The result is sensor packages that are smaller, lighter, and can be produced at speeds up to 250 units per minute.

By the numbers

250 units/min

Target throughput for sensor package fabrication

50%

Improved accuracy over conventional methods

20%

Improved automation

100x

Reliability improvement factor

Consortium partners

75%

Industry partner ratio in consortium

SMEs in consortium

The business problem

What needed solving

Automotive RADAR and LIDAR sensors are too large, heavy, and power-hungry to integrate seamlessly into car bodies like bumpers and headlamps. Current manufacturing methods are slow, inflexible, and produce inconsistent quality — making miniaturized, high-volume sensor production a major bottleneck for the autonomous driving industry.

The solution

What was built

The project built a complete pilot production platform combining inkjet-printed conductive and dielectric inks, nano-imprint lithography for optical components, AI-driven pick-and-place assembly, and inline inspection using thermography and spectroscopy. They demonstrated small-series fabrication of both RADAR and LIDAR sensor packages on this integrated pilot line.

Audience

Who needs this

Tier-1 automotive sensor suppliers (Continental, Bosch, Valeo)Microelectronics packaging houses looking to add additive manufacturing capabilityLIDAR and RADAR module manufacturers for autonomous vehiclesIndustrial inkjet equipment integratorsRobotics companies needing miniaturized perception sensors

Business applications

Who can put this to work

Automotive electronics

enterprise

Target: Tier-1 or Tier-2 automotive sensor suppliers

If you are an automotive sensor supplier struggling with bulky RADAR or LIDAR packages that won't fit inside bumpers or headlamps — this project developed a pilot production platform that achieves throughput up to 250 units/min with 50% improved accuracy and 20% more automation. The additive manufacturing approach reduces material waste and eliminates costly tooling changes when switching between sensor designs.

Semiconductor packaging

mid-size

Target: Microelectronics packaging and assembly houses

If you are a semiconductor packaging company dealing with expensive retooling every time a sensor design changes — TINKER built an additive manufacturing pilot line with inkjet-printed conductive inks, dielectric materials, and inline inspection. The platform uses closed-loop error compensation between devices, improving reliability by a factor of 100 compared to conventional methods.

Industrial automation and robotics

SME

Target: Manufacturers of autonomous mobile robots and drones

If you are building autonomous robots or drones and need miniaturized, high-performance LIDAR sensors at competitive cost — this project demonstrated small-series fabrication of both RADAR and LIDAR sensor packages using a fully integrated pilot platform. The pick-and-place system uses AI software to improve accuracy, with 3D inspection and laser ellipsometry built in.

Frequently asked

Quick answers

What would it cost to adopt this production approach?

The project data does not include specific pricing or cost-per-unit figures. However, the additive manufacturing approach eliminates traditional tooling costs and reduces material waste, which typically lowers per-unit cost for small and medium production runs. Contact the consortium for a cost comparison against your current packaging process.

Can this scale to industrial production volumes?

Yes. The TINKER platform targets throughput up to 250 units per minute, which is a production-grade speed. The project delivered a pilot line with inkjet systems installed at an industrial partner (BOS) and demonstrated small-series fabrication of both RADAR and LIDAR sensor packages.

What is the IP situation — can I license this technology?

The consortium includes 16 partners across 8 countries, with 12 industrial partners and 5 SMEs. IP arrangements would be governed by the consortium agreement. Based on available project data, individual equipment components (inkjet, NIL, placement, inspection) were developed by specific partners who likely hold the respective IP rights.

How reliable are the sensors produced this way?

The project objective states reliability improved by a factor of 100 compared to conventional fabrication. This is achieved through closed-loop error compensation between devices and inline inspection using thermography, spectroscopy, and microscopy.

What types of sensors can this platform produce?

The platform was demonstrated with two sensor types: RADAR and LIDAR packages for automotive applications. The underlying additive manufacturing techniques — inkjet printing, nano-imprint lithography, and automated placement — are adaptable to other microelectronic sensor packages that require miniaturization.

Is this ready for my production line today?

The project delivered functional prototypes and small-series demonstrators, placing it at pilot stage. The pilot line was installed at an industrial partner site. Further engineering and qualification steps would be needed before full production deployment in your facility.

Consortium

Who built it

The TINKER consortium is heavily industry-driven with 12 out of 16 partners (75%) coming from industry, including 5 SMEs — a strong signal that this technology was built with commercial deployment in mind, not just academic publication. The 8-country spread across Austria, Czech Republic, Germany, Greece, Finland, France, Israel, and Italy covers major European automotive and electronics manufacturing hubs. The coordinator PROFACTOR is an Austrian applied research organization specializing in industrial automation. With 3 research organizations providing the science backbone and zero universities, this consortium was clearly assembled to move technology from lab to factory floor.

PROFACTOR GMBHCoordinator · AT
P.V. NANO CELL LTDparticipant · IL
AUSTRIAN STANDARDS INTERNATIONAL -STANDARDISIERUNG UND INNOVATIONparticipant · AT
INFINEON TECHNOLOGIES AUSTRIA AGthirdparty · AT
ROBERT BOSCH GMBHparticipant · DE
EV GROUP E. THALLNER GMBHparticipant · AT
COMMISSARIAT A L ENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVESparticipant · FR
TIGER Coatingsparticipant · AT
INFINEON TECHNOLOGIES AGparticipant · DE
IDRYMA TECHNOLOGIAS KAI EREVNASparticipant · EL
INKRON OYparticipant · FI
BESI AUSTRIA GMBHparticipant · AT
AMIRES SROparticipant · CZ

How to reach the team

PROFACTOR GMBH (Austria) — applied research organization specializing in industrial automation. Use SciTransfer's coordinator lookup to find the right contact.

Order a report on this consortium See PROFACTOR GMBH profile →

Next steps

Talk to the team behind this work.

Want an introduction to the TINKER team to discuss licensing or pilot testing? SciTransfer can connect you directly with the right technical lead.

Order a report on this topic More in Manufacturing & Industry 4.0