Gonvarri Industries MS R&D — Electronic sensor printing

EMI Project — Intelligent Metallic Structures through electronically printed sensors

The EMI Project — Intelligent Metal Structures is based on the research of printed electronics for the development of sensors that monitor these types of structures and allow the transmission of high-value information on the state of structural health remotely.

What problems want to solve or improve?

The general objective of the project lies in the design of a sustainable digital printing process capable of developing electronic sensors for monitoring metallic structures, providing an intelligent system that allows high-value information on the state of structural health to be transmitted remotely.

This project involves the development of complex systems, the electronic printing process and the design of sensors compatible with the technology and application.

Which digital technology addresses the issue?

The project aims to design and validate a sustainable digital printing process through the development of a prototype consisting of a strain gauge, its associated electronics and an RFID communication antenna for monitoring metal structures in industrial use cases.

Printed electronics is an innovative and promising additive manufacturing technology that offers several advantages over traditional electronics manufacturing. Its ability to produce flexible, cost- and time-efficient and environmentally friendly devices makes it an excellent choice for a wide variety of applications.

The development of state-of-the-art sensors and antennas using advanced printed electronic technology marks an important breakthrough in the integration of sophisticated electronic functionalities into metallic structures.

To achieve the overall objective, the following technical objectives are required:

1. Identification and selection of printing materials, such as conductive inks or substrates, compatible with the metallic structures to be monitored, prioritising those that facilitate longer sensor lifetime, reusability, or recyclability of the sensors. The limitations of the materials in terms of their conductivity should be assessed, evaluating the possibility of using dielectric materials.
2. Definition of a digital printing process capable of solving complex 2D and 3D designs for the production of electronic sensors. It will be necessary to parameterise the deposition trajectories, speed, and material supply to guarantee the precision of the process.
3. Design of electronic elements for the sensorisation of the structure and transmission of information. Within the framework of the project, the design, and development of the aforementioned strain gauge and an RFID communication antenna will be carried out, as well as the associated electronic components.
4. Design and development of structural prototypes for the validation of the technology to enable the integration of printed sensors or direct printing. To this end, the metal structures to be monitored will be defined and sensor validation tests will be carried out to assess the functionality of the sensors.

What are the results, and what is the impact?

The EMI Project — Intelligent Metallic Structures Through Electronic Sensor Printing constitutes industrial research, since it involves planned research to obtain new knowledge in printed electronics for the development of electronic sensors that enable the monitoring of metallic structures.

The printing of electronic sensors has a transversal character, being able to monitor any parameter that can be transformed into an electrical signal. It also includes the construction of prototypes for the validation of the generic technology.

The results of the project can be extrapolated to the development of new products, processes, or services in industrial sectors such as those related to construction (civil engineering) or aeronautics, among others, being characteristic of the types of structures studied.

Collaborators of the EMI Project — Intelligent Metallic Structures

The project involves the participation of eight expert entities in the various disciplines it covers. All eight will contribute their experience and knowledge, guaranteeing the success of the project. In addition to Gonvarri and our partners FEMETALiNDUSTRY and Idonial, Rotimpres, Tafco Metawireless, Khisgroup, the Functional Print cluster and TSK Electrónica y Electricidad are involved.

This is a project funded by the Ministry of Industry and Tourism through the 2023 Call for Innovative Business Clusters, within the framework of the Spanish Government’s Recovery, Transformation and Resilience Plan.

About Gonvarri Industries

Gonvarri Industries was founded in 1958 and has continued its growth by expanding globally and diversifying. It is a leader in the steel and aluminium transformation business, with an emphasis on sustainable, profitable growth and continuous improvement of products and services with the aim of strengthening relationships with customers and suppliers.

In the service centres, the metal is subjected to a series of high-tech processes that enable the product to be tailored to the customer’s needs.

As an expert in the steel sector, Gonvarri Industries defines the following business units: Service Centres, Metal Structures, Material Handling and Precision Tubes.

Gonvarri MS R&D, the R&D centre of Gonvarri Metal Structures, is participating in the ‘Intelligent Metal Structures through electronic sensor printing’ project.