Advancing Automotive Innovation with Hybrid Electronics

Driving the Future of Mobility

NextFlex is the nation’s hub for hybrid electronics (HE) innovation and manufacturing readiness. As a public-private partnership and Manufacturing Innovation Institute, NextFlex bridges the gap between lab and line – accelerating U.S. manufacturing capabilities while strengthening domestic industry and driving technology transitions in defense applications. NextFlex brings together industry, academia, and government to commercialize HE technologies.

What are Hybrid Electronics?

Hybrid Electronics combine the performance and durability
of traditional electronics with the versatility and conformability of non-traditional materials and processing. This innovative approach enables the embedding of sensors, circuits, and communication devices directly onto novel, flexible substrates and traditional automotive materials. With HE capabilities, viable electronics substrates now include non-traditional electronics materials such as woven carbon fiber, polymers such as PVC and PET, textile fabrics, leather, and glass. Specific benefits include: expanding design freedoms, reducing weight, reducing manufacturing complexity, and increasing reliability.

THE FUTURE of automotive electronics

In automobiles, hybrid electronics enable advanced human–machine interfacing, with touch-sensitive controls on steering wheels, consoles, and interior panels. Heated armrests, integrated displays, and capacitive surfaces enhance driver interaction while reducing complexity. Printed strain and impact sensors provide structural health monitoring, while conformal antennas deliver vehicle-to-everything connectivity. Structurally integrated electronics and sensors built directly into vehicle body panels reduce wiring, save weight, and open new possibilities for design and safety. For defense ground vehicles, ruggedized touch panels and conformal RF antennas further enhance performance in the harshest environments.

Hybrid electronic focus areas in automobiles include:

Interior lighting harnesses
A/C harnesses
Rear/side view mirror harnesses
Seat harnesses
Window lift harnesses
HDLP/LED headlight harnesses
Tail light/RCL harnesses
Transaxle harnesses
Under hood harnesses
Side marker harnesses
Camera harnesses
Arm rest harnesses
Convertible top harnesses
Center high mount stop lamp (CHSML) harnesses
Engine position sensor harnesses
Shift level cable assemblies
Circuit board jumpers
And more

But innovation is not enough—reliability is critical. Hybrid electronics must endure extreme conditions: the constant vibration of engines and roadways, the heat and cold of high-altitude flight, the vacuum and radiation of space, and the thermal cycling of vehicle operation. NextFlex and its members are developing rigorous test methods and reliability standards to ensure hybrid electronics perform in the world’s most demanding environments.

Join us at the NextFlex Workshop on Hybrid Electronics for Automotive and Aerospace Applications or connect with us to explore the latest breakthroughs, share challenges, and shape the future of electronics manufacturing.

PARTNERING WITH NEXTFLEX FOR COMPETITIVE ADVANTAGE

INDUSTRY IMPACT OF HYBRID ELECTRONICS

Energy Efficiency & Fuel Economy

Reduction in fuel/energy consumption by integrating lightweight, flexible hybrid circuits that reduce overall vehicle mass.
Improvement in energy efficiency through better thermal management and power distribution using embedded sensors and smart electronics.

Performance & Reliability

Faster signal transmission in critical systems (e.g., ADAS, infotainment) due to shorter interconnects and optimized layouts.
Increased system uptime with predictive maintenance enabled by embedded diagnostics and real-time monitoring.

Safety & Compliance

Reduction in wiring harness complexity, lowering the risk of electrical faults and improving crash safety.
Improved EMI shielding and compliance with ISO 26262 standards for functional safety in automotive electronics.

Manufacturing & Cost Efficiency

Reduction in assembly time by integrating multiple functions into a single hybrid module.
Lower total cost of ownership (TCO) over the vehicle’s lifecycle due to fewer mechanical connectors and reduced maintenance needs.

WHY BECOME A NEXTFLEX MEMBER?

The corporations, small businesses, universities, community colleges, and government organizations that make up our membership bring subject matter expertise to the member community. Cross-collaboration across the organizations means that NextFlex members are always learning and growing. They discuss state-of-the-art technologies that are revolutionizing the electronics industry and cooperate on projects that foster technology innovation and commercialization. Membership with NextFlex also offers the following benefits:

Accelerated Prototyping

NextFlex’s Technology Hub in San Jose, CA, offers pilot-scale prototyping, manufacturing tools, and engineering expertise to speed product development. We offer concept, design, engineering, and prototyping services all the way through to manufacturing readiness. Learn more about how we can help you incorporate hybrid electronics technologies and fabrication into your designs or help you solve any manufacturing challenges you might have.

Robust Ecosystem

NextFlex brings together the technologies and capabilities of over 200 members and associates throughout the manufacturing supply chain, representing world-class
expertise and capabilities.
The Automotive Technical Working Group is composed of government, industry, and academic leaders, and identifies technology gaps, defines roadmaps, and guides collaborative projects that advance hybrid electronics for automotive applications.

Tailored Support

We can help you with your organization’s needs by:
- Mentoring/assisting qualified small- and medium-sized manufacturers, including providing engineering and design services.
- Supporting small business recipients in prototyping & developing proof of concept demonstrations for DoD projects.
- Helping organizations de-risk technology/capital equipment adoption by enabling the evaluation of tool capabilities that exist at the NextFlex technology hub for their applications prior to investing in new equipment.
- Providing manufacturing support from early prototype through low-volume manufacturing (if appropriate).
- Assisting with transitioning/scaling of production to a U.S. volume manufacturer.

NextFlex’s Protoyping and Manufacturing Services

In support of our mission to advance hybrid electronics manufacturing in the U.S., our facility has two cleanrooms and lab space for electronics printing, device integration and testing and measurement, that are fully compliant with ITAR’s (International Traffic in Arms Regulations) quality standard requirements for military electronics, materials, and guidance equipment manufacturing as well as the Food and Drug Administration’s (FDA) medical device manufacturing Quality Systems Regulations (QSR) for good manufacturing practices.

Working with NextFlex, a robust community of innovators including start-up companies and established manufacturers alike, are benefiting from a collaborative approach to electronics design, development and problem-solving via our state-of-the-art hybrid electronics technology hub. You can view the equipment list here.

You do not need to be a NextFlex member to use our manufacturing services. Contact us to learn more.

Custom Nextflex Workshops: Smarter electronics

In addition to access to our equipment, NextFlex also offers training and education opportunities in hybrid electronics. We work with individuals and groups of all sizes to build HE competencies at all organizational levels. We can match your program and project needs with specific pieces of equipment at our facility. Additionally, with our hands-on training format, you can explore use of dozens of tools and techniques which can be applied to shape and deliver your design and production requirements. Contact us to learn more about how we can help you train your team.

BUILDING THE FUTURE OF AUTOMOTIVE TOGETHER

We are ready to start the conversation. Let’s collaborate to deliver smarter, safer, and more efficient vehicles for tomorrow. Learn more by sending us an email at info@nextflex.us.