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This paper aims to study the effect of the thermoforming process on the assembly of a newly developed stretchable material for electric circuit and LEDs for manufacturing of automotive lighting. The thermoforming process was conducted using a mould developed based on commercially available automotive lighting product. The circuit was initially printed on a flat thermoplastic substrate using screen printing technique prior to the thermoforming process. The quality of the product was investigated before and after thermoforming process through quantitative measurement and visual inspection in terms of the circuit’s resistivity and the electrical conductivity, respectively. The resistivity measurement was conducted by using four point probes instrument to compare the resistivity of the circuit which depends on stretch level of circuit and substrate during the thermoforming process. The stretch level was found to be different along the geometry due to the unsymmetrical geometry of the mould. The electrical conductivity of the circuit was also tested by LEDs illumination through power supply connection. This study shows promising results in applying thermoforming process in the fabrication of 3-dimensional shape product with lower cost equipment.This paper aims to study the effect of the thermoforming process on the assembly of a newly developed stretchable material for electric circuit and LEDs for manufacturing of automotive lighting. The thermoforming process was conducted using a mould developed based on commercially available automotive lighting product. The circuit was initially printed on a flat thermoplastic substrate using screen printing technique prior to the thermoforming process. The quality of the product was investigated before and after thermoforming process through quantitative measurement and visual inspection in terms of the circuit’s resistivity and the electrical conductivity, respectively. The resistivity measurement was conducted by using four point probes instrument to compare the resistivity of the circuit which depends on stretch level of circuit and substrate during the thermoforming process. The stretch level was found to be different along the geometry due to the unsymmetrical geometry of the mould. The electrical con...

A study on thermoforming process of stretchable circuit and its performance in manufacturing of automotive lighting