Wacker starts serial production of flexible sensor electronics

Munich, Germany – Wacker has launched serial production of sensor laminates based on flexible printed electronics, marking what it described as “a new stage” in the commercialisation of stretchable capacitive devices.

The laminates, said Wacker 3 Sept, are made from stacks of “highly stretchable insulating and electrically conductive silicone rubber films.”

Produced using “a specially developed and fully automated roll-to-roll manufacturing process,” the stacks jointly work as “a flexible and stretchable capacitor.”

According to Wacker, pressure or flex movements change the electrical capacitance of the component, thereby different capacity states prove “precise sensor signals for applications in medical technology, robotics and sports.”

Wacker is presenting the laminates at K 2025 in Dusseldorf 8–15 Oct.

“For the first time, we are presenting ourselves as a manufacturer of prefabricated components, ready for mass production and integration,” said the German group.

The laminates are produced in layer thicknesses of 20–200 microns, comparable to human hair.

They are said to offer elasticity, dimensional stability, UV resistance, biocompatibility, and recovery after "millions of load cycles."

Wacker is also using ‘laser structuring’ which allows fine electrode geometries with a pixel size of 100 microns.

Designs, according to the Munich-based group, can be modified “in seconds” within the production line, enabling customisation from prototypes to large series.

The company also confirmed plans to start serial production in 2026 of an actuator version – Nexipal Act – which deforms under electrical voltage to create smooth, silent movements.

Wacker said the material will be suited for robotics, automotive and medical applications involving human–machine interaction.