Dr. Zachary J. DAVIS

Under his leadership, the DTI printed electronics group pursues cutting-edge research initiatives encompassing sustainable materials, smart textiles, and advanced manufacturing processes. The group’s comprehensive expertise spans multiple domains, including the development of environmentally conscious ink formulations, optimisation of screen-printing processes for scale-up operations, and the creation of sophisticated embedded sensor systems. Their work extends to seamlessly integrating electronic components within textiles and optimising power management systems for smart garments.

Zachary’s methodical approach to documentation and quality control ensures that innovative designs successfully transition from laboratory concepts to mass-producible products. His strategic oversight of flexible electronics development has established new benchmarks in sustainable electronic manufacturing. By combining his technical acumen with strong leadership skills, he continues to drive transformative projects that advance the convergence of sustainable electronics and textile engineering, pushing the boundaries of what’s possible in smart fabric technology.

The situation is expected to worsen, with projections indicating e-waste generation will reach 82 million tonnes by 2030 [Earth.org]. This trajectory not only poses significant environmental risks but also represents a substantial loss of valuable resources. The inadequate recycling of electronic components results in the annual waste of approximately US $91 billion worth of valuable metals [UNITAR].

In response to these challenges, there is an urgent need for innovative approaches that can transform the electronics industry towards more sustainable and circular practices. This is particularly crucial in the field of printed electronics, which represents a growing sector with significant potential for implementing circular economy principles from the design phase.

Danish Technological Institute (DTI) is coordinating the Horizon Europe project Sustain-a-Print, which focuses on developing sustainable and circular materials and processes for printed electronics. This initiative directly addresses the critical challenges of electronic waste management and resource conservation in the electronics industry.

The project encompasses several key innovations aimed at reducing environmental impact and improving resource efficiency:

1. Development of novel screen printable copper inks, offering a more sustainable alternative to traditional materials
2. Print process optimisation techniques focused on reducing energy & material consumption
3. Implementation of de-bondable and re-usable electrical components
4. Development of efficient recycling processes for high value materials

Through these innovations, Sustain-a-Print aims to demonstrate that circular economy principles can be successfully integrated into printed electronics manufacturing, potentially setting new standards for sustainability in the industry. The presentation will provide detailed insights into these developments and their potential impact on reducing electronic waste while conserving valuable resources.

This work represents a significant step toward addressing the growing e-waste crisis while promoting more sustainable practices in electronics manufacturing. By focusing on both material innovation and process optimisation, the project demonstrates how technological advancement can be aligned with environmental stewardship.