Apparatus and method for creating flexible circuits

Abstract

A method and apparatus for forming a flexible circuit of predetermined design, and in particular to the making of a functioning flexible circuit by depositing multiple layers of a variety of materials in fluid or component form in a set configuration onto a substrate. A source for each of the materials is provided. In one embodiment, the materials are applied to the substrate through accurate positioning and moving of the dispensing heads in three dimensions and through accurate control of the amount of material applied. In some embodiments, the substrate is a flexible film. In some embodiments, successive layers of electronic circuitry are formed by successively printing and then curing each layer, one on top of the last, starting with a flexible substrate, such as polyester film. Not only are conductive traces (i.e., wiring) printed (i.e., by dispensing and curing properly selected fluids) using the methods and/or systems described below, but also passive components (such as, for example, resistors, capacitors, and/or inductors), and/or active components (such as, for example, transistors, switches, amplifiers, filters, electric batteries, memory and/or logic).