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Multilayer Printed Components Serve Emerging Markets
February 28, 2007 |Estimated reading time: 3 minutes
REDWOOD CITY, Calif. EoPlex Technologies is introducing two major products created using the company's proprietary printing process. Arthur Chait, CEO of EoPlex, described high-volume print forming (HVPF) as a technology that suits emerging markets, filling a previously unmet need, and using a different route in established sectors. "We have a platform technology with HVPF," he said, "similar in scale to some of the process technologies developed for SMT." The company recently received $8 million in series C funding, which will partially finance increased capacity for an energy harvester for tire-pressure sensors and a fuel cell reformer that the company developed.
The printing process is used to generate layers, building devices with multiple materials and substrates, and integrating complex geometries into one component. "We can print a spiral structure within a device, as well as microfluidic channels, and 3-D circuits," explained Chait. Diverse materials, such as ceramic dielectrics, metals, silica, alumina, and glasses can often by fired together. This process creates component suited to harsh environments, restricted space, and unusual form factors.
EoPlex used HVPF to manufacture an energy harvester to replace batteries in tire-pressure sensors, as well as a catalytic reformer to power fuel cells. The energy harvester taps into the lucrative market of tire-pressure sensors, Chait said, because of the Tread Act of 2000, government legislation requiring that new cars include tire-pressure sensors to alert drivers of dangerous changes in pressure, as well as economic and safety pressures from consumers. The company's customer believes the energy harvester will preclude the need for batteries to power these sensors, reducing the size of the sensor's assembly, and creating an autonomous system for the high-reliability unit. "It could become a separate product group within the company at some point, because of the market potential," added Chait.
The company's second major application for HVPF is a miniature catalytic reformer, developed for a multinational OEM for hydrogen-powered fuel cells. "We don't make fuel cells," said Chait. "Our product is like a miniature catalytic chemical plant converting alcohol to hydrogen to supply the OEM's fuel cell." To produce the fuel cell reformer, EoPlex dispenses 300 layers of different materials, incorporating various units and geometries into the device, then firing it all together. "We can create a power for emergency radios of first responders and replace low-functioning, expensive, heavy batteries." Test have shown that the reformer will replace ten pounds of conventional batteries with one pound of alcohol, which supplies the hydrogen, for long-term battery use in chaotic situations, according to the company. Chait gave Hurricane Katrina as an example of a time in which battery life challenged rescue workers.
EoPlex, through the energy harvester, reformer, and other products, focuses resources on emerging markets in high-reliability spaces. As a customer-driven start-up, the company is developing products for a niche to address previously unmet needs primarily in industrial markets. "We are not looking to break into the near-term market for consumer-item batteries, where devices are designed with low power consumption in mind." This market is a longer-term option. EoPlex also designs components in the high end of assembly products. "An EoPlex component may be substantially lower in cost than the conventional solution, which could even comprise several components and assemblies, but the printed component is specialized, still above the few-cents-per commodity."
Chait sees potential with large OEMs in automotive, military, aerospace, and similar industries. "We can move to market more quickly by partnering with OEMs that possess specified knowledge and certifications for a given industry," he explained. These certifications can be costly and extensive, and the majority of OEM customers already have proper certifications. EoPlex works with customers to develop a component that is compatible with the OEM's requirements, but is not required to invest in military and government certification programs.