Silicon Austria Labs, Austria; Mimotype, Germany
This project is a collaboration between an RTO (SAL) and an SME (MimoType) and demonstrates how light therapy for muscle recovery is elevated to the next level by integrating ultra-conformal circuitry directly into a wearable sleeve. The key enabler is printed hybrid electronics on TPU foil, which allows seamless heat-press transfer to textiles. This innovation ensures that therapeutic light is delivered comfortably, effectively, and unobtrusively, even during movement.
Key Features
- Next-level light therapy enabled by ultra-conformal hybrid circuitry.
- Printed on TPU foil for flexibility, stretchability, and skin comfort.
- Heat-press transfer to textiles, ensuring seamless integration into wearables.
- Thin, lightweight, and robust design suitable for active use.
- Demonstrates printed electronics as the enabler for new generations of health wearables.
Impact on society: This technology brings professional recovery therapy into everyday life through lightweight, wearable systems, enhancing comfort and effectiveness
Functionality
The demonstrator is based on a multi-layer printed hybrid circuit fabricated directly on a TPU foil. First, a stretchable silver ink is deposited by screen printing and thermally cured to form the initial conductive layer. Next, an insulating layer is applied and UV-cured to provide electrical isolation and mechanical stability. A second conductive layer is then printed on top, completing the circuit layout. Discrete optoelectronic components (red light emitters) and SMD resistors are glued onto the circuit to form the functional device. The entire structure is then heat-press transferred onto a textile substrate, enabling a soft, ultra-conformable wearable that follows body movements without losing performance. Once powered, the hybrid circuit activates the red-light emitters, which deliver therapeutic light directly to the muscles, promoting recovery.
Benefits of the project
This project demonstrates how printed electronics uniquely enable next-generation light therapy wearables. Unlike conventional rigid or semi-flexible circuits, the multi-layer printed structure on TPU foil provides ultra-thin, stretchable, and conformable circuitry that can be seamlessly integrated into textiles. This means the wearable moves naturally with the body while maintaining reliable performance – a feature not possible with standard PCB technologies. The use of additive manufacturing also reduces resource usage and generates less waste, as well as supports scalable, cost-efficient production.
Target Industry
- Healthcare & Rehabilitation – wearable recovery devices for physiotherapy, sports medicine, and preventive health.
- Consumer Electronics & Wearables – integration into fitness and wellness products.
- Sports & Fitness Industry – professional and everyday recovery solutions.
Organic & Printed Components
- Conductive path
- Interconnection
- Printed dielectric / insulator
- Printed electrode
Classical Components
- LED Panels
- SMD Capacitors,
- SMD Inductors,
- SMD Diodes,
- timer IC,
- LED driver IC.