Printed Circuitry

Printed Flexible Circuits

flexible rigid printed circuits conductive inks PET PEN PI GSIManufacturing utilizing 100% additive printing processes offers a low cost means to produce many unique flex circuit designs. GSI services numerous customers with our conductive printing capabilities, and with our years of experience printing conductive, resistive, and dielectric materials on a variety of flexible and rigid substrates. Most customer designs are unique and require GSI’s expertise in matching ink characteristics with print processes and end product performance attributes. GSI has scaled many challenging circuit designs requiring:

  • Produce sheet samples and seamlessly scale to roll processing
  • Delivery of parts in roll or sheeted formats
  • Double sided circuits with and without printed thru-holes (vias)
  • Roll to roll capabilities allow processing thin gauge substrates
  • Very broad printed substrate selection: polyester (PET, PEN), polycarbonate (PC), paper, polyimide (PI), polyetherimide (PEI), and most other films
  • Adding printed features to copper flex or rigid circuit boards
  • Integral material selection utilizing silver, carbon, and dielectrics.

Printed Circuits for Wearable Electronics

Flexible wearable electronics dielectric inks thermoplastic polyurethane printed GSI garment strechableThe wearable electronics market represents a broad and diverse offering of commercial products that is forecasted to grow into a multi-billion dollar a year industry. GSI Technologies is at the forefront of manufacturing and leading development efforts on wearable products where printing solves technical issues. GSI utilizes ink sets including Silver (Ag), Silver/Silver Chloride (Ag/AgCl), carbon, and dielectric inks from multiple vendors. These inks sets are specially designed for use with flexible substrates. The flexible substrates have included a variety of TPU (thermoplastic polyurethane) based materials. Along with materials knowledge, GSI is able to use its manufacturing capabilities such as sheet or roll based through hole printing and high precision laser converting to enable new product designs. With our downstream converting partners, wearable parts can also have adhesive applied, be final packaged, and sterilized.


Printed Circuitry Capabilities

GSI’s printed electronics manufacturing expertise is fully capable across most polymer thick film constructions specializing in printed silver flex circuits. Investments and partnerships enable capabilities to produce single, double sided, and multi-layer circuits. Capabilities exist to pre-process film or paper substrates with selective place openings (vias) or surface chemistry prior to creating 100% additive conductive structures. Available capabilities include:

  • Conductive circuit printing in sheet and roll to roll format
  • Substrate widths: 500 mm web and 600 mm sheet
  • Handling of films down to 2 mils in thickness
  • Experienced with traditional conductive inks and many new technology developments (nanoparticle systems)
  • Ability to change the design resistance by 9 orders of magnitude through ink selection
  • Full range of UV and thermal curing systems
  • Multi-layer flex circuits including thru hole printing (vias)
  • Laser ablation of transparent conductors
  • Secondary die cutting by hard tool or laser
  • Statistical process control
  • Dedicated engineering team to assist in manufacturing flow optimization


GSI Printed Circuit Advantages

flexible rigid printed circuits conductive ink PET PEN PI GSIEquipment

GSI has the knowledge and the established partner relationships to help customers at every stage of manufacturing, from prototypes all the way to global scale production. Installed manufacturing base includes the ability to make a single device to volumes in excess of billions. Printing assets will deposit conductive, resistive, and insulating inks, while laser processing and laminating creates unique functional structures. Ability to produce high layer count products (excess of 10 layers). Sheet or roll form product is supplied depending on customer requirements. Many manufacturing lines utilize 100% electrical testing for continuous process control and continuous vision systems for defect detection.


Extremely broad range of materials selection including silver, silver/silver chloride, carbon, graphene, nickel, iron, tungsten, bismuth, zinc, PEDOT, and blends such as platinized carbon. Processing ITO films with IR laser ablation.

GSI services numerous customers with our conductive printing capabilities. We have formulated strategic partnerships in North America, Europe, and Asia to satisfy market demands for secondary operations.


GSI has an extensive and very broad engineering team with collective experience in excess of 150 years. The GSI team has helped many companies solve difficult technical problems not solved by other manufacturing partners.


Flat-bed print lines are utilized to support early stage process development and for producing production representative prototypes. As volume grows our roll-to-roll print lines have the print speed and drying capacity to support high volume requirements. In excess of 14 billion sensors have been produced on GSI’s installed manufacturing base.


All application development and manufacturing is performed within an ISO 9001 and ISO 13485 certified quality system. Automated print lines are outfitted with proven vision inspection and 100% real time electrical testing supported by statistical process control systems ensuring high yields and consistent product quality.

Our team includes experienced engineers and a full service art department that is prepared to meet your manufacturing requirements.
Click to visit our engineering page.

If you are looking for printing solutions for medical, industrial, automotive, or consumer products, give us a call at
630-325-8181. Let’s work together to find a solution that fits.

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