With the start of serial production of Nexipal Sense sensor laminates, Wacker is moving its flexible printed electronics activities from material supply to prefabricated components ready for integration. The silicone laminate functions as a flexible and stretchable capacitor, in which pressure or bending changes the electrical capacitance and yields precise sensor signals for applications in medical technology, robotics and sports. The multilayer stack is produced on a fully automated roll-to-roll line. Each insulating or electrically conductive film layer is based on addition-curing silicone rubber. Typical individual film thickness ranges from 20 to 200 micrometers, while a human hair is roughly 50 micrometers. The laminates are designed for elasticity, dimensional stability and toughness, are skin-friendly and biocompatible, are UV resistant and withstand temperatures from minus 40 to plus 180 degrees Celsius. According to the company, they maintain high recovery and elasticity even after millions of load cycles, which the manufacturer highlights as an advantage compared with conventional materials. At K 2025 the company will present itself as a manufacturer of prefabricated components for the first time, offering customized parts ready for mass production and integration.
Roll-to-roll manufacturing and digital electrode patterning
The structured layers consist of specially developed electrically conductive silicones and are composed using digital laser printing techniques. With a resulting pixel of about 100 micrometers, very fine electrode geometries are achievable. "The flexibility and scalability we offer today is unique on the market," said Senior Business Development Manager Johannes Neuwirth. In a matter of seconds, designs can be changed directly within the process. The shape or number of layers can also be adjusted at the touch of a button, enabling configurations from prototypes to batches of millions. In-line quality controls with AI-assisted image processing ensure consistent precision for each layer, with accuracy of approximately ±5 micrometers in layer thickness.
Wacker has recently started serial production of its sensor laminates Nexipal Sense. At the K 2025 plastics trade show, Wacker will be presenting the market-able product laminate for sensor applications for the first time. (Photo: Wacker)
Sustainability, trade fair exhibit and roadmap
Wacker states that the sensor laminates are produced using electricity from the company’s own photovoltaic system. The entire process runs at low temperatures and does not involve rare earths, solvents or heavy metals. "Our high-performance sensor laminates are performant, durable and sustainably produced at the highest level," underlined Neuwirth. At K 2025 in Düsseldorf the company will present an interactive exhibit for hands-on testing of the sensor laminates in Hall 6, Booth A10, from October 8 to 15.
The company is also preparing an actuator version of the laminate, Nexipal Act, planned to enter serial production in 2026. These silicone laminates deform and create movement when an electrical voltage is applied, enabling precise, smooth and silent actuation for applications in human-machine interaction, including robotics, automotive and medical technology.
Wacker will be showcasing Nexipal Sense at the K 2025 plastics trade show. Pressure or stretching movements of the electroactive silicone laminate generate different voltage states that provide precise sensor signals for applications in medical technolog
