Sustainable Production Insight Through LCA and LCC Analysis of Injection Overmolded Structural Electronics Manufactured through Roll-to-Roll Processes

Printed electronics (PE) have provided new material and application opportunities for devices and systems as well as new manufacturing routes that all need to be considered for commercialization. This paper introduces a case study with universally relevant manufacturing processes and applications in the PE area, focusing on the Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) of the Personal Activity Monitor (PAM) device. In the study, the PAM device's most important costs and environmental impacts during the prototype pilot production and device use phases are identified and assessed. Additionally, the potential environmental impacts of post-consumption scenarios are considered. The LCA results indicate that the roll-to-roll (R2R) assembly of electronics and the R2R injection over-molding are generally the most prominent production process steps affecting the results. From the LCC perspective, the capitial expenditure (CAPEX) contributor is the R2R assembly pilot line, due to its high investment cost and long operating time compare to other production assets. The traditional electronic components are the major operating expenditures (OPEX), especially the microcontroller units (MCUs) and accelerometers, in contrast to the low impact from the printed electronics. There are several advantages to applying LCA and LCC since they provide explanations of the relationships between cost, environmental, design, and manufacturing characteristics.