How a Small Screen-Printing Change Improved Heater Performance

Can a small change in the screen-printing process improve the performance of a printed heater? Butler Technologies partnered with MicroScreen to investigate whether a specialized nano-surface treatment could improve carbon paste release and transfer during screen printing. The study compared treated and untreated screen areas while keeping the other process variables consistent. The team evaluated print thickness, electrical resistance, and thermal performance to determine whether changes in material transfer could translate into measurable improvements in the finished heater. The results showed that treated screens produced a slightly thicker carbon deposit, with an increase of approximately 3%. The treated heaters also demonstrated lower electrical resistance, higher operating temperatures, and faster heating response. Additional testing using a different carbon ink system produced similar results, suggesting that the approach may have broader potential across printed electronics applications. This case study explores how a relatively subtle manufacturing process improvement can influence: Carbon paste transfer Printed deposit thickness Electrical resistance Heating performance Heating response time Printed heater design For manufacturers and engineers working with screen-printed heaters and printed electronics, the study demonstrates why optimizing individual manufacturing steps can have meaningful effects on final product performance. Learn more about Butler Technologies: https://butlertechnologies.com/ #ScreenPrintedHeaters #PrintedElectronics #ScreenPrinting #Engineering #CaseStudy