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This BCC Research report provides new insights on flexible devices that are produced using R2R technologies, as well as outlines technological trends and offer an updated market analysis for these products. Includes forecast through 2020.

Use this report to:

Gain infomation about various device types and roll-to-roll fabrication processes
Receive information about the technological issues, including key events and the latest process developments for R2R flexible devices
Identify opportunities for process and productivity improvements and new product developments
Gain technical insights into the R2R manufacturing of flexible devices

Highlights

The global market for flexible devices manufactured by roll-to-roll (R2R) technologies totaled $14.6 billion in 2015 and is expected to reach $28.1 billion by 2020 increasing at a compound annual growth rate (CAGR) of 13.9% from 2015 to 2020.
Electronic devices as a segment should reach $13.7 billion in 2015 and $23.3 billion by 2020, with a CAGR of 11.2% through the forecast period.
Optoelectronic devices segment of this market will increase from $670 million in 2015 to $3.3 billion by 2020, a CAGR of 37.2% for the period of 2015-2020.


STUDY GOALS AND OBJECTIVES

There is growing interest in advanced devices that are thin, lightweight and bendable.
Generally known as flexible devices, these products include primarily electronics, optoelectronics, and energy devices, although other types, such as sensors and medical devices, are also beginning to emerge.

As flexible devices become more popular, the need for high-volume processes for their fabrication increases. Consequently, the industry is steadily transitioning to the integration of roll-to-roll (R2R) technologies for the fabrication of these devices.

BCC Research first published its R2R technologies and flexible devices report in April 2013. The market for these products has since experienced healthy growth, while new technological developments and industry changes have also taken place.

The primary goal of this report is to provide new insights on flexible devices that are produced using R2R technologies, as well as to outline technological trends and offer an updated market analysis for these products.

Specifically, the major objectives of this study are:

To provide an updated review of commercially available and emerging flexible devices, including a description of their types and fabrication technologies.
To highlight new technological developments in flexible device manufacturing, while outlining current technical issues.
To review various processes that are being used for R2R manufacturing, focusing on those that are quickly gaining in popularity.
To estimate current global markets for flexible devices produced by R2R technologies based on device type, manufacturing process, substrate material, and region, with growth forecasts through 2020 for each market segment.
To identify important technology and industry trends within each market segment.
To offer an updated review of current industry players, including manufacturers of devices, materials, fabrication equipment, technology developers, and future market participants.
To provide a description of the most relevant research and development activities.
To determine trends in recently issued U.S. patents.

REASONS FOR DOING THIS STUDY

Although the first flexible circuits were produced in the early 1900s, introduction of R2R technologies for manufacturing these circuits occurred many years later in Japan during the 1980s. The use of R2R methods has become more common, while various processes have been adapted for applications in creating patterns on flexible substrates.

The need to produce advanced devices on a large scale with high throughput, low cost, and high quality, while at the same time using fabrication methods that are environmentally friendly and energy efficient is also leading to the rapid expansion of the printed electronics market. This market is currently valued at approximately $9
billion and is estimated to grow at a robust rate during the five-year period between 2015 and 2020.
The availability of various printing methods adapted to R2R processing represents a major contributing factor to the current and future expansion of the flexible device market.

The principal reason for this report is to present a current assessment of the R2R flexible device industry from both a technological and market point of view, as well as outline future trends and key developments.

There is also a need to evaluate the current status and future trends of this market from a global standpoint. As the use of these products expands and new fields of application emerge, information on suppliers and developers of these devices and their regional distribution becomes more valuable.

Table Of Contents

Global Markets for Roll-to-Roll Technologies for Flexible Devices
CHAPTER 1 INTRODUCTION 2
STUDY GOALS AND OBJECTIVES 2
REASONS FOR DOING THIS STUDY 3
INTENDED AUDIENCE 3
SCOPE OF REPORT 4
METHODOLOGY AND INFORMATION SOURCES 5
RELATED BCC RESEARCH REPORTS 6
ANALYST'S CREDENTIALS 7
BCC RESEARCH WEBSITE 8
DISCLAIMER 8
CHAPTER 2 EXECUTIVE SUMMARY 10
SUMMARY TABLE GLOBAL MARKET FOR FLEXIBLE DEVICES MANUFACTURED BY
R2R TECHNOLOGIES, THROUGH 2020 ($ MILLIONS) 11
SUMMARY FIGURE GLOBAL MARKET FOR FLEXIBLE DEVICES MANUFACTURED BY
R2R TECHNOLOGIES, 2013-2020 ($ MILLIONS) 11
CHAPTER 3 OVERVIEW 13
INTRODUCTION 13
DEFINITION AND STUDY FOCUS 13
R2R VERSUS BATCH PROCESSES 13
IMPORTANCE OF FLEXIBLE DEVICES AND R2R PROCESSES 14
MILESTONES IN THE HISTORY OF R2R FLEXIBLE DEVICES AND RECENT EVENTS 15
TABLE 1 R2R FLEXIBLE DEVICES-TECHNOLOGICAL MILESTONES 16
FIGURE 1 NUMBER OF GLOBAL FLEXIBLE DEVICES PATENTS ISSUED, 1970-2014 17
CURRENT AND EMERGING FLEXIBLE DEVICES PRODUCED BY R2R
TECHNOLOGIES 18
TABLE 2 FLEXIBLE DEVICES MANUFACTURED BY R2R TECHNOLOGIES, 2015 18
ELECTRONIC DEVICES 18
Flexible Printed Circuits 19
Other Circuit Devices 19
Other Electronic Devices 19
OPTOELECTRONIC DEVICES 20
Electrochromic Displays 20
TABLE 3 ELECTROCHROMIC MATERIALS, 2015 21
Inorganic Electrochromic Materials 21
Organic Electrochromic Materials 22
Electrolyte 23
Counter-Electrodes 23
Electrophoretic Displays 24
Basic Design 24
Microcapsule Design 24
Polymer Dispersed Liquid Crystal Displays 25
Encapsulation 25
Phase Separation 25
Holography 26
Prefabricated Templates 26
Organic Light Emitting Diode Displays 27
Basic Design 27
Solid-State Lighting Devices and Roll Tablets 27
ENERGY DEVICES 28
Solar Cells and Modules 28
Other Energy Devices 29
SENSORS AND OTHER DEVICES 30
CHAPTER 4 ROLL-TO-ROLL TECHNOLOGIES 32
INTRODUCTION 32
BASIC ROLL-TO-ROLL FABRICATION PROCESS 32
TABLE 4 BASIC ROLL-TO-ROLL FABRICATION STEPS, 2015 32
SUBSTRATE SELECTION 33
TABLE 5 SUBSTRATE MATERIALS FOR R2R MANUFACTURING, 2015 35
FILM DEPOSITION AND PATTERNING 35
SUBTRACTIVE METHODS 35
Substrate Coating 35
TABLE 6 THICK-FILM COATING TECHNOLOGIES, 2015 36
TABLE 7 THIN-FILM COATING TECHNOLOGIES, 2015 37
Lithography 41
Optical Lithography 41
Immersion Lithography 41
Nanostencil Lithography 42
Deep Ultraviolet Light Lithography 42
X-Ray Lithography 42
Electron Beam Lithography 42
Reflective E-beam Lithography 42
Ion Beam Lithography 43
Scanning Probe Lithography 43
Dip-pen Nanolithography 43
Nanoimprint 43
Thermoplastic Nanoimprint Lithography 43
Photo Nanoimprint Lithography 44
Laser-assisted Direct Imprint 44
Self-Aligned Imprint Lithography 44
Extreme Ultraviolet Lithography 44
Directed Self Assembly 45
Nanomotor Lithography 45
TABLE 8 LITHOGRAPHIC METHODS, 2015 45
Etching 46
ADDITIVE METHODS 46
TABLE 9 PRINTING TECHNOLOGIES, 2015 46
Screen Printing 47
Stencil Printing 48
Gravure 48
Direct Gravure 48
Reverse Gravure 49
Offset Gravure 49
Smooth Roll Gravure 49
Microgravure 49
Pad Printing 49
Flexography 50
Transfer Printing 50
Offset Lithography 50
Micropen Printing 50
Extrusion Printing 51
Inkjet Printing 51
Continuous Inkjet Printing 51
Drop-on-Demand Inkjet Printing 51
Thermal 52
Piezoelectric 52
Electrostatic 52
Acoustic 52
Phase-Change 52
Organic Vapor Jet Printing 53
Laser Printing 53
Micro-Spray Printing 53
Aerosol Jet Printing 53
Electrophotography 54
Ionography 54
Magnetography 54
Nanography 54
Thermography 54
Most Common Additive Processes 55
MULTI-LAYER STRUCTURES 55
CURING 55
ASSEMBLY, CUTTING, TESTING AND PACKAGING 55
LATEST TECHNOLOGICAL DEVELOPMENTS FROM 2013 TO PRESENT 56
CAPACITIVE TOUCH SENSOR CIRCUITS BY R2R PRINTING 56
HYBRID PRINTING SYSTEM 56
R2R MICROCONTACT PRINTING SYSTEM 58
ELECTROCHROMIC GEL FOR STRETCHABLE DISPLAYS 59
CONJUGATED ELECTROCHROMIC POLYMER 59
R2R FABRICATION OF ELECTROACTIVE POLYMERIC TRANSDUCERS 60
SILVER INK FOR INKJET PRINTING ON FLEXIBLE SUBSTRATES 61
OTHER RELEVANT RandD ACTIVITIES 61
TABLE 10 OTHER RELEVANT R andD ACTIVITIES, 2015 62
CHAPTER 5 GLOBAL MARKETS 65
ANALYSIS OUTLINE 65
GLOBAL MARKET SUMMARY 65
TABLE 11 GLOBAL MARKET FOR R2R FLEXIBLE DEVICES, THROUGH 2020 ($
MILLIONS) 66
FIGURE 2 GLOBAL MARKET FOR R2R FLEXIBLE DEVICES, 2013 TO 2020 ($
MILLIONS) 66
CURRENT MARKET STATUS 67
CURRENT MARKET SUMMARY 67
TABLE 12 CURRENT MARKET FOR R2R FLEXIBLE DEVICES, THROUGH 2015 ($
MILLIONS) 67
FIGURE 3 CURRENT MARKET FOR R2R FLEXIBLE DEVICES, 2013 TO 2015 ($
MILLIONS) 68
REVENUES BY DEVICE TYPE 68
TABLE 13 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY TYPE, THROUGH 2015
($ MILLIONS) 69
FIGURE 4 CURRENT MARKET SHARE FOR R2R FLEXIBLE DEVICES BY TYPE, 2015 (%) 69
REVENUES BY PROCESS 70
TABLE 14 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY PROCESS, THROUGH
2015 ($ MILLIONS) 71
FIGURE 5 CURRENT MARKET SHARE FOR R2R FLEXIBLE DEVICES BY PROCESS,
2015 (%) 71
REVENUES BY SUBSTRATE MATERIAL 72
TABLE 15 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY SUBSTRATE
MATERIAL, THROUGH 2015 ($ MILLIONS) 72
FIGURE 6 CURRENT MARKET SHARE FOR R2R FLEXIBLE DEVICES BY SUBSTRATE
MATERIAL, 2015 (%) 72
REVENUES BY REGION 73
TABLE 16 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY REGION, THROUGH
2015 ($ MILLIONS) 74
FIGURE 7 CURRENT MARKET SHARE FOR R2R FLEXIBLE DEVICES BY REGION, 2015
(%) 74
MARKET GROWTH TRENDS 75
INDUSTRY GROWTH AND TECHNOLOGICAL TRENDS 75
Electronics 75
TABLE 17 GLOBAL MARKET FOR SEMICONDUCTORS BY REGION, THROUGH 2020 ($
BILLIONS/%) 75
Printed Circuit Boards and Flexible Printed Circuits 76
Portable Computers and Tablets 76
TABLE 18 GLOBAL MARKET FOR PORTABLE COMPUTERS, ULTRA-LIGHT
CHROMEBOOKS AND TABLETS, 2015 AND 2020 ($ BILLIONS) 77
Smartphones 77
RFIDs 77
Smart Cards 77
Thin-Film Devices 78
Printed Electronics 78
Micro- and Nanoelectromechanical Systems 79
TABLE 19 GLOBAL MARKET FOR MEMS AND NEMS BY TYPE, 2015 AND 2020 ($
BILLIONS) 79
Flexible Hybrid Devices and Wearable Electronics 79
Optoelectronics 80
Advanced Displays 80
TABLE 20 GLOBAL MARKET FOR ADVANCED DISPLAYS BY TYPE, THROUGH 2020 ($
BILLIONS) 81
FIGURE 8 GLOBAL MARKET SHARE FOR ADVANCED DISPLAYS BY TYPE, 2015 AND
2020 (%) 81
Paper-thin and Flexible Displays 82
Digital Signage 83
Solid-state Lighting Devices 83
Energy 83
Photovoltaic Cells 83
TABLE 21 GLOBAL PRODUCTION FOR PHOTOVOLTAIC MODULES BY TYPE,
THROUGH 2020 (MW) 84
FIGURE 9 GLOBAL PRODUCTION SHARE FOR PHOTOVOLTAIC MODULES BY TYPE,
2020 (%) 84
Flexible Solar Cells 85
Batteries 85
Supercapacitors 86
Fuel Cells 86
TABLE 22 GLOBAL MARKET FOR FUEL CELLS BY TYPE, THROUGH 2020 ($ MILLIONS) 86
Thermoelectric Devices 87
Sensors and Other Devices 87
TABLE 23 GLOBAL MARKET FOR SENSORS BY TYPE, THROUGH 2020 ($ MILLIONS) 87
Flexible Sensors 88
Biosensors 88
TABLE 24 GLOBAL MARKET FOR BIOSENSORS AND OTHER COMMON SENSORS,
THROUGH 2020 ($ BILLIONS) 89
Medical Devices 89
OTHER TECHNOLOGICAL TRENDS 89
New Substrate Materials for Roll-to-Roll Processes 89
Pattern Deposition Processes 89
TABLE 25 FILM OR FEATURE THICKNESS ACHIEVABLE BY DIFFERENT PRINTING
METHODS, 2015 (NANOMETERS) 90
Advanced Materials for High Pattern Resolution 90
Energy and Environmental Factors 91
REGIONAL TRENDS 91
MARKET FORECAST 92
REVENUES BY DEVICE TYPE 92
TABLE 26 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY TYPE,
THROUGH 2020 ($ MILLIONS) 93
FIGURE 10 GLOBAL MARKET SHARE FORECAST FOR R2R FLEXIBLE DEVICES BY
TYPE, 2020 (%) 93
REVENUES BY PROCESS 94
TABLE 27 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY PROCESS,
THROUGH 2020 ($ MILLIONS) 94
FIGURE 11 GLOBAL MARKET SHARE FORECAST FOR R2R FLEXIBLE DEVICES BY
PROCESS, 2020 (%) 95
REVENUES BY SUBSTRATE MATERIAL 96
TABLE 28 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY SUBSTRATE
MATERIAL, THROUGH 2020 ($ MILLIONS) 96
FIGURE 12 GLOBAL MARKET SHARE FORECAST FOR R2R FLEXIBLE DEVICES BY
SUBSTRATE MATERIAL, 2020 (%) 96
REVENUES BY REGION 97
TABLE 29 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY REGION,
THROUGH 2020 ($ MILLIONS) 98
FIGURE 13 GLOBAL MARKET SHARE FORECAST FOR R2R FLEXIBLE DEVICES BY
REGION, 2020 (%) 98
CHAPTER 6 GLOBAL INDUSTRY STRUCTURE 100
LEADING MANUFACTURERS OF FLEXIBLE DEVICES BY R2R TECHNOLOGIES 100
TABLE 30 LEADING MANUFACTURERS OF FLEXIBLE DEVICES BY R2R
TECHNOLOGIES, 2015 100
TABLE 31 LEADING MANUFACTURERS OF FLEXIBLE DEVICES BY R2R
TECHNOLOGIES BY DEVICE TYPE, 2015 103
TABLE 32 LEADING SUPPLIERS OF FLEXIBLE DEVICES BY R2R TECHNOLOGIES BY
DEVICE TYPE AND REGION, 2015 105
LEADING PRODUCERS OF MATERIALS FOR FABRICATION OF FLEXIBLE DEVICES
BY R2R TECHNOLOGIES 105
TABLE 33 LEADING PRODUCERS OF MATERIALS FOR FABRICATION OF R2R
FLEXIBLE DEVICES, 2015 105
OTHER PLAYERS IN THE R2R INDUSTRY 107
TABLE 34 OTHER RELEVANT INDUSTRY PLAYERS, 2015 107
COMPANY PROFILES 111
3M 111
ACREO/PAPERDISPLAY 112
ASCENT SOLAR TECHNOLOGIES 113
AVERY DENNISON 114
E INK HOLDINGS 115
E Ink Corp. 115
Acquisition of E Ink 116
Acquisition of Sipix Imaging 116
Current Activities 116
EMFIT 117
FLEXIUM INTERCONNECT 118
FUJIKURA 118
GSI TECHNOLOGIES 119
JOHNSON ELECTRIC 120
KENT DISPLAYS 121
KONICA MINOLTA 123
LG DISPLAYS 123
LINXENS 124
MATERION 125
MFLEX 127
MOLEX 127
MULTEK 128
NIPPON MEKTRON LTD. 129
NITTO DENKO 130
POWERFILM 131
SAMSUNG ELECTRONICS 131
SUMITOMO ELECTRIC 132
THIN FILM ELECTRONICS 133
ZHEN DING TECHNOLOGY 134
CHAPTER 7 U.S. PATENT ANALYSIS 136
INTRODUCTION 136
SUMMARY OF PATENTS AWARDED DURING THE PERIOD 2013 THROUGH 2015 136
TABLE 35 R2R FLEXIBLE DEVICES - U.S. PATENTS, 2015 136
TABLE 36 R2R FLEXIBLE DEVICES - U.S. PATENTS, 2014 137
TABLE 37 R2R FLEXIBLE DEVICES - U.S. PATENTS, 2013 139
GENERAL TRENDS 140
TABLE 38 U.S. PATENT RELATED TO R2R FLEXIBLE DEVICES, 2010 TO 2015 141
FIGURE 14 U.S. PATENT RELATED TO R2R FLEXIBLE DEVICES, 2010-2015 (NUMBER
OF PATENTS) 142
TRENDS BY COUNTRY AND REGION 142
FIGURE 15 SHARES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES BY
REGION, 2013-2015* (%) 142
FIGURE 16 U.S. PATENT RELATED TO R2R FLEXIBLE DEVICES BY COUNTRY,
2013-2015* (NUMBER) 144
TRENDS BY ASSIGNEE 144
TABLE 39 ASSIGNEES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES,
2013-2015* 145
FIGURE 17 SHARES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES BY
ORGANIZATION TYPE, 2013-2015* (%) 147
TRENDS BY PATENT CATEGORY 148
FIGURE 18 SHARES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES BY
CATEGORY, 2013-2015* (%) 148
TRENDS BY PROCESS 149
FIGURE 19 SHARES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES BY
PROCESS, 2013-2015* (%) 150
TRENDS BY DEVICE TYPE 151
FIGURE 20 SHARES OF U.S. PATENTS RELATED TO R2R FLEXIBLE DEVICES BY TYPE,
2013-2015* (%) 152

LIST OF TABLES

SUMMARY TABLE GLOBAL MARKET FOR FLEXIBLE DEVICES MANUFACTURED BY R2R
TECHNOLOGIES, THROUGH 2020 ($ MILLIONS) 11
TABLE 1 R2R FLEXIBLE DEVICES-TECHNOLOGICAL MILESTONES 16
TABLE 2 FLEXIBLE DEVICES MANUFACTURED BY R2R TECHNOLOGIES, 2015 18
TABLE 3 ELECTROCHROMIC MATERIALS, 2015 21
TABLE 4 BASIC ROLL-TO-ROLL FABRICATION STEPS, 2015 32
TABLE 5 SUBSTRATE MATERIALS FOR R2R MANUFACTURING, 2015 35
TABLE 6 THICK-FILM COATING TECHNOLOGIES, 2015 36
TABLE 7 THIN-FILM COATING TECHNOLOGIES, 2015 37
TABLE 8 LITHOGRAPHIC METHODS, 2015 45
TABLE 9 PRINTING TECHNOLOGIES, 2015 46
TABLE 10 OTHER RELEVANT R andD ACTIVITIES, 2015 62
TABLE 11 GLOBAL MARKET FOR R2R FLEXIBLE DEVICES, THROUGH 2020 ($
MILLIONS) 66
TABLE 12 CURRENT MARKET FOR R2R FLEXIBLE DEVICES, THROUGH 2015 ($
MILLIONS) 67
TABLE 13 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY TYPE, THROUGH 2015
($ MILLIONS) 69
TABLE 14 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY PROCESS, THROUGH
2015 ($ MILLIONS) 71
TABLE 15 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY SUBSTRATE MATERIAL,
THROUGH 2015 ($ MILLIONS) 72
TABLE 16 CURRENT MARKET FOR R2R FLEXIBLE DEVICES BY REGION, THROUGH
2015 ($ MILLIONS) 74
TABLE 17 GLOBAL MARKET FOR SEMICONDUCTORS BY REGION, THROUGH 2020 ($
BILLIONS/%) 75
TABLE 18 GLOBAL MARKET FOR PORTABLE COMPUTERS, ULTRA-LIGHT
CHROMEBOOKS AND TABLETS, 2015 AND 2020 ($ BILLIONS) 77
TABLE 19 GLOBAL MARKET FOR MEMS AND NEMS BY TYPE, 2015 AND 2020 ($
BILLIONS) 79
TABLE 20 GLOBAL MARKET FOR ADVANCED DISPLAYS BY TYPE, THROUGH 2020 ($
BILLIONS) 81
TABLE 21 GLOBAL PRODUCTION FOR PHOTOVOLTAIC MODULES BY TYPE, THROUGH
2020 (MW) 84
TABLE 22 GLOBAL MARKET FOR FUEL CELLS BY TYPE, THROUGH 2020 ($ MILLIONS) 86
TABLE 23 GLOBAL MARKET FOR SENSORS BY TYPE, THROUGH 2020 ($ MILLIONS) 87
TABLE 24 GLOBAL MARKET FOR BIOSENSORS AND OTHER COMMON SENSORS,
THROUGH 2020 ($ BILLIONS) 89
TABLE 25 FILM OR FEATURE THICKNESS ACHIEVABLE BY DIFFERENT PRINTING
METHODS, 2015 (NANOMETERS) 90
TABLE 26 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY TYPE,
THROUGH 2020 ($ MILLIONS) 93
TABLE 27 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY PROCESS,
THROUGH 2020 ($ MILLIONS) 94
TABLE 28 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY SUBSTRATE
MATERIAL, THROUGH 2020 ($ MILLIONS) 96
TABLE 29 GLOBAL MARKET FORECAST FOR R2R FLEXIBLE DEVICES BY REGION,
THROUGH 2020 ($ MILLIONS) 98
TABLE 30 LEADING MANUFACTURERS OF FLEXIBLE DEVICES BY R2R TECHNOLOGIES,
2015 100

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