Demonstrator showcases smarter and more sustainable electronics for automotive lighting

DP Patterning and ams OSRAM, a global leader in innovative light and sensor solutions, have developed a joint demonstrator that illustrates how future automotive lighting can be produced more cost-efficiently and with a significantly lower CO₂ impact.

The Open System Protocol (OSP) solution from ams OSRAM provides automotive manufacturers greater freedom in designing and controlling vehicle lighting. Combined with the smart LED driver AS1163, hundreds of light points, sensors, and actuators can be connected through a single continuous line. This creates a simplified electronics architecture of the lighting system that reduces the need for complex multilayer PCBs, enabling the use of DP Patterning’s sustainable printed flexible circuits.

“By combining the expertise of ams OSRAM in intelligent LED control with DP Patterning’s flex PCB technology, we unlock new design freedom for automotive interiors. This approach not only adapts to complex shapes but is also paving the way for more sustainable automotive interior lighting elements and effects,” emphasizes Andrea Maria Saraceno, Application Engineer at ams OSRAM.

The collaboration has been underway since April 2025 and the demonstrator was showcased for the first time at the productronica trade fair in Munich in November.

“By using our innovative flexible circuits, customers gain a more cost-afficient solution while drastically reducing environmental impact. We are very pleased that ams OSRAM has demonstrated a concrete way of applying our circuits in a smart, energy-efficient solution. We are now looking for more partners from various industries, who are interested in exploring the possibilities through pilot projects and hopefully scaling production together. The potential is enormous,” says Staffan Nordlinder, CEO of DP Patterning.

Sustainable and cost-efficient electronics

The major environmental advantage of DP Patterning’s flexible circuits lies in the manufacturing process. The patented Dry Phase Patterning (DPP) replaces traditional wet etching with a dry, chemical-free method. By mechanically patterning the metal layer instead of using chemicals, the environmental impact of the manufacturing process is reduced by up to 98 percent. Switching from expensive silver to aluminium, a far more abundant and affordable material, significantly reduces the material cost. Faster production speed and easier handling of finished products make the process even more cost-efficient.

Scalable production

Developed and refined in Norrköping, Sweden, DP Patterning’s technology has evolved into a scalable solution for sustainable electronics manufacturing. Today, DP Patterning supplies flexible and sustainable PCBs to leading companies worldwide across industries such as automotive, consumer electronics, communications, MedTech, aviation and industrial solutions. The next step is to establish easily installed micro-plants designed for regional, high-volume production, which will bring the manufacturing closer to the customer.

Contact us to learn more

Tommy Höglund, Global Sales Director
Tommy.hoglund@dppatterning.com
Mobile: +46 72 245 46 74

Helena Schauer, ams OSRAM press contact
Helena.Schauer@ams-osram.com
press@ams-osram.com

The full press release is available on Cision.

About DP Patterning 

Pioneering sustainable electronics manufacturing!

DP Patterning manufactures custom-made flexible PCB components with sustainability at the core. Our patented Dry Phase Patterning (DPP) technology replaces hazardous chemical etching with a clean, reel-to-reel mechanical process — cutting CO₂ emissions by up to 98%, while reducing lead times, logistics, and waste.

Engineered in Sweden and trusted by globally leading companies in automotive, LED lighting, RFID/NFC, connectivity, defence, consumer electronics, industrial electronics, avionics, and MedTech, we deliver high-performance, scalable, and cost-efficient solutions.

We are scaling global capacity and building regional production units to make electronics manufacturing more local, resilient, and accessible.

Find out more about DP Patterning: DP Patterning LinkedIn  https://dppatterning.com/

About ams OSRAM

The ams OSRAM Group (SIX: AMS) is a global leader in innovative light and sensor solutions. 

With more than 110 years of industry experience, we combine engineering excellence and global manufacturing with a passion for cutting-edge innovation. Our commitment to pushing the boundaries of illumination, visualization, and sensing enable transformative advancements in the automotive, industrial, medical, and consumer industries.

“Sense the power of light” – our success is based on the deep understanding of the potential of light and our distinct portfolio of both emitter and sensor technologies. Approximately 19,700 employees worldwide focus on pioneering innovations alongside the societal megatrends of digitalization, smart living and sustainability. This is reflected in over 13,000 patents granted and applied. Headquartered in Premstaetten/Graz (Austria) with co-headquarters in Munich (Germany), the group achieved EUR 3.4 billion revenues in 2024 and is listed as ams-OSRAM AG on the SIX Swiss Exchange (ISIN: AT0000A3EPA4). 

Find out more about ams Osram on https://ams-osram.com

ams and OSRAM are registered trademarks of ams OSRAM Group. In addition, many of our products and services are registered or filed trademarks of ams OSRAM Group. All other company or product names mentioned herein may be trademarks or registered trademarks of their respective owners.  

Join ams OSRAM social media: >LinkedIn  >Facebook  >YouTube

DP Patterning at Productronica 2025!

We’re excited to announce that DP Patterning will be exhibiting at Productronica 2025, the world’s leading trade fair for electronics development and production. Productronica 2025 will take place in Munich, Germany November 18th -21th.

Visit us at Hall B2 Booth 506!

Our Dry Phase Patterning method enables cost-efficient, chemical-free, and highly conductive production of flexible circuits using solid aluminum on a variety of substrates — from plastics to paper. The result:

• Up to 98% lower carbon emissions compared to traditional wet etching.
• Significant cost reduction at volume production.
• Superior conductivity versus silver ink printing methods.
• Secure and resilient sourcing.

At Productronica, we will present our latest innovations in sustainable electronics manufacturing, including DPP produced applications for LED, flat panel antennas, flexible circuits and more. Visitors will see how DPP enables greener, faster, and more scalable production — perfectly suited for modern electronics and IoT solutions.

Mobile communication has evolved tremendously in recent decades, from the 1G analog networks and bulky cellular devices of the 1980s to the 5G networks that currently support our ultra-fast Internet and Internet of Things (IoT) connectivity. At the foundation of all this mobile communication are antennas, effectively the bridge between electronic devices and wireless networks. Now, as we prepare to enter into a new era of 6G network technology—defined by even faster speeds, ultra-low latency, and more sophisticated IoT devices—the demand for higher-performing antennas is increasing, along with the demand for raw materials used in antenna production, such as silver and other precious metals. 

In light of this antenna market growth, the question of cost and sustainability is paramount. Specifically, we must contend with how to meet this increasing production demand while mitigating environmental impact and cost challenges through the reduction of valuable raw material consumption and energy usage. Sweden-based DP Patterning, inventor of the Dry Phase Patterning (DPP) manufacturing process for flexible electronics, is positioning its technology as a solution.  

The hurdles on the road to green antennas

Methods like wet chemical etching, and silver ink printing have traditionally been used to manufacture antennas. Unfortunately, these processes fall short when it comes to sustainable antenna production. As Duncan Platt, Unit Manager of Printed Electronics at the Research Institute of Sweden (RISE), explains: “Wet etching and chemical-based processes generate hazardous waste and consume significant amounts of water and energy. Silver ink printing, for its part, requires several steps—printing, drying, and curing—that take time and add complexity.” 

“DP Patterning provides a cleaner, lower-energy, chemical-free process. The metal swarf removed by milling is recyclable. According to an independent study conducted by the Fraunhofer Institute, the DP Patterning solution, if applicable, can reduce the equivalent carbon dioxide footprint by approximately 98%.”
Duncan Platt, Unit Manager of Printed Electronics at the Research Institute of Sweden (RISE)

Common antenna production approaches are also plagued by other challenges. For instance, CNC milling is notoriously slow, which limits the scalability and throughput of antenna production in high-volume applications. From a material standpoint, the use of conductive materials like silver inks can drive up production costs, particularly as material prices are subject to market volatility. “The supply of printed circuit boards and precious metals like silver can present sourcing issues in times of geopolitical turbulence,”  Duncan emphasizes. “Furthermore, printed silver traces often achieve only 10–30% of bulk silver conductivity, affecting performance.”

Meeting the growing demand for high-performance antennas required for widespread 6G rollout—in a sustainable way—thus requires a different approach, one that delivers on scale, cost, and efficiency. That’s where Dry Phase Patterning comes in. 

DPP unlocks sustainability, cost savings, and productivity

DP Patterning’s patented DPP technology offers an alternative to more conventional antenna production techniques that is more sustainable, cost-efficient, and productive. 

The technology is based on a roll-to-roll mechanical milling process that uses a cliché to pattern an aluminum, copper, or copper-clad aluminum laminate. Once the pattern (with a minimum gap width of 100 µm and pattern pitch down to 400µm) has been applied to the laminate, a precision milling wheel mills away the pattern from the top layer of the laminate, resulting in a substrate with conductive traces. As a mechanical process, DPP does not require the use of any hazardous chemicals, inks, or freshwater. On top of that, the metal removed in the milling process can be fully recycled, resulting in virtually no waste.

Duncan explains the ecological significance of this process: “DP Patterning provides a cleaner, lower-energy, chemical-free process. The metal swarf removed by milling is recyclable. According to an independent study conducted by the Fraunhofer Institute, the DP Patterning solution, if applicable, can reduce the equivalent carbon dioxide footprint by approximately 98%.”

DPP is also more cost-efficient than competing processes for antenna design and production. This is primarily driven by material costs, as aluminum is far cheaper and more cost stable than bulk copper and silver. DP Patterning reports that companies can significantly reduce costs by using aluminum laminate instead of silver ink. 

Of course, conductivity is an important consideration for any antenna, and copper is king when it comes to this specific property. With this in mind, Duncan specifies that DP Patterning can provide patterned aluminum with conductivity levels equivalent to conventional copper printed circuit boards if that level of conductivity is required simply by increasing the design thickness. Generally, though, a standard aluminum substrate provides a sufficient degree of conductivity (for example, the standard 9µm thick aluminium can reach two to three times the conductivity of printed silver ink). In tests comparing a DPP RFID tag to a conventional RFID tag, DP Patterning found that they had the same frequency range, while the former also benefited from a smaller CO2 footprint.

In terms of productivity, DPP has the capacity to produce up to 30 meters of patterned single-layer substrate per minute—up to 10 times faster than conventional processes. Using a magnetic roll-to-roll system and an easy-swap tooling system, DP Patterning’s solution can also easily switch between pattern designs, unlocking design flexibility and customization. The rate at which DPP hardware can turn out antennas is also reinforced by the fact that antenna manufacturers can benefit from localized production thanks to DP Patterning’s micro plants, minimizing the reliance on unstable global supply chains and dramatically reducing lead times and emissions associated with logistics and transport. 

DPP antenna applications 

Antenna geometries and topologies vary greatly depending on performance factors like signal strength and frequency range, as well as overall goals like durability, sustainability, and cost. DP Patterning’s technology is equipped to manufacture a range of different antenna designs, from miniaturized, mass-produced antennas integrated into IoT devices, to large-area array antennas used for radar and satellite communications.

The table below covers a selection of the antenna types that Dry Phase Patterning is well-suited for:

“Antennas are almost ubiquitous these days so the DP Patterning technology can support the innovation drive, as a sustainable alternative, towards all kinds of applications with a growing demand for high-performance, low-cost antennas, such as 5G/6G, smart infrastructure, and more,” Duncan says. Looking forward, DPP technology could play an important role in transitioning antenna manufacturing towards greater efficiency and sustainability. 

Are you attending the European Microwave Week? Visit DP Patterning at Stand B138 to learn more about DP Patterning’s patented DPP technology and how it can benefit the manufacturing process for specific antenna applications, get in touch with us company today.

DP Patterning just published an article on Wevolver (a leading engineering knowledge platform). Discover how Dry Phase Patterning (DPP) showcased a 99 percent reduction both in carbon footprint and electricity used compared to conventional wet etching. – read all about it in the article!

DP Patterning at LOPEC – sustainable flex-PCB production

DP Patterning is excited to announce our active participation in the 2024 edition of LOPEC, the premier trade fair for flexible, organic, and printed electronics worldwide. The LOPEC exhibition and conference will take place at the ICM, München, from March 6–7, 2024, providing a comprehensive platform for showcasing innovations in research and development, mass production, and various application domains within the flexible and printed electronics industry. DP Patterning will present its 98-99% reduction in Global Warming Potential, aligning with its commitment to sustainable flex-PCB production.

Collaboration at LOPEC

At LOPEC, DP Patterning will collaborate with other industry leaders, including Norrköping Science Park, Ligna Energy, Epishine, Cellfion, N-ink, ParsNord and RISE, to exhibit at a joint booth, B0.412. Together, we will highlight the advanced capabilities of the DPP 360 flex-PCB production system and demos.

We extend a warm invitation for you to visit Booth 412, where you can engage with us and our fellow exhibitors in B:412. Throughout the event, we will be presenting products and solutions applicable to diverse sectors, including automotive (EVs), RFID, LED light, energy, and real estate. Join us at LOPEC to explore cutting-edge advancements and innovations in the flexible and printed electronics industry.

Conference presentation “sustainable flex-PCB production” – by Roman Armgarth

Our R&D manager Roman Armgarth, will give a presentation at the LOPEC Conference. Romans session offer valuable insights into how the DPP 360 system is transforming the flex-PCB manufacturing landscape, by enhancing environmental sustainability, enabling in-house flex-PCB production, and cutting costs. Moreover, Roman will explain the unique process advantages of Dry Phase Patterning especially over etching, such as the in-line adjustment of resistance via the milling depth.

Time and place: Thursday March 7th, 14:40 – 15:00 in Room 13a at the LOPEC Congress.

Fill in the form to get your LOPEC tickets.

98% lower environmental impact

DP Patterning will present its 98-99% reduction in Global Warming Potential, aligning with its commitment to sustainable flex-PCB production. Traditional etching employs hazardous chemicals and expensive production processes. The chemicals used need special handling, storage conditions, permits and facility investments. By making a change from etching to the DPP 360 system, you can produce flex-circuits in a swift and controlled process without emissions, risky handling, or toxic waste. There is no need for safety gear, air purification or wastewater treatment. By insourcing your production, you eliminate the negative effects of overseas shipping. For example, our own customers calculate more than 98% reduction in Global Warming Potential compared to the traditional chemical etching process.