Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
IPC-6901: Printed Electronics Categories, Levels & Performance Criteria by Application
When you’re developing a printed electronics product, one of the first questions that comes up is: what performance requirements apply to my application? A medical sensor has vastly different reliability demands than a smart packaging tag. IPC-6901 provides the classification framework that answers this question, establishing market categories and assembly levels that define appropriate performance criteria for printed electronics across every major industry segment.
Having worked with printed electronics projects spanning consumer wearables to automotive sensors, I’ve found IPC-6901 indispensable for setting realistic performance targets and communicating requirements to suppliers. This guide explains how to use the standard’s dual classification system effectively.
What is IPC-6901?
IPC-6901, officially titled “Application Categories for Printed Electronics,” is a joint IPC/JPCA standard that establishes classification systems for printed electronics products and assemblies. Published in July 2015, IPC-6901 was developed by the Printed Electronics Final Assembly Subcommittee (D-64) in collaboration with the JPCA Printed Electronics Committee.
Document Attribute
IPC-6901 Details
Full Title
Application Categories for Printed Electronics
Document Number
IPC/JPCA-6901
Joint Development
IPC and JPCA
Publication Date
July 2015
Developed By
Printed Electronics Final Assembly Subcommittee (D-64)
Primary Purpose
Classification systems and performance criteria
Unlike traditional PCB standards that focus on manufacturing specifications, IPC-6901 takes an application-centric approach. The standard helps engineers classify their printed electronics products by market segment and assembly complexity, then provides appropriate performance criteria and testing methods for each classification.
Purpose and Scope of IPC-6901
The primary purpose of IPC-6901 is to provide printed electronics developers with a structured classification framework for designing and manufacturing products that conform to industry-established performance metrics. The standard accomplishes this through three key elements.
Market Classification System: Eleven categories covering major application sectors from aerospace to smart packaging.
Level Classification System: Four levels defining assembly complexity from passive components to complete products.
Performance Framework: Lists of performance criteria and testing methods applicable to each classification.
IPC-6901 applies to both traditional printed electronics (fully printed circuitry) and Flexible Hybrid Electronics (FHE) that combine printed and conventional components. This dual coverage reflects the reality that most commercial printed electronics products incorporate some conventional elements.
IPC-6901 Market Classification System
The IPC-6901 market classification system organizes printed electronics applications into eleven categories based on end-use market segment. Each category carries different performance expectations and regulatory requirements that influence design decisions.
Category Overview Table
Category
Market Segment
Key Characteristics
1
Aerospace
Extreme reliability, harsh environments
2
Automotive
Temperature extremes, vibration, long life
3
Consumer Electronics & Communications
Cost-sensitive, moderate reliability
4
Home/Domestic Robotics
Safety-critical, consumer interaction
5
Industrial & Commercial Controls
Durability, environmental exposure
6
Medical
Biocompatibility, regulatory compliance
7
Military
Extreme conditions, mission-critical
8
Building Materials
Long service life, environmental stability
9
Smart Packaging
Low cost, single use, food safety
10
Smart Grid
Outdoor exposure, grid integration
11
Future
Emerging applications
Aerospace Applications (Category 1)
Category 1 covers printed electronics for aerospace applications where failure is not an option. These products must operate reliably in extreme conditions including rapid temperature cycling, high altitude pressure differentials, radiation exposure, and significant vibration loads.
Category 2 addresses the automotive industry’s demanding requirements for printed electronics. Automotive applications face temperature extremes from cold-start conditions to under-hood heat, continuous vibration exposure, and expected service lives often exceeding 15 years.
Typical Applications:
Interior touch surfaces and controls
Seat occupancy sensors
In-mold electronics for dashboards
Flexible heating elements
Battery monitoring systems for EVs
Performance Priorities: Wide temperature range operation, vibration durability, long service life, automotive qualification testing (AEC-Q).
Consumer Electronics and Communications (Category 3)
Category 3 encompasses the high-volume consumer electronics market where printed electronics enables new form factors and reduces manufacturing costs. Cost optimization often takes priority over extreme reliability requirements.
Typical Applications:
Wearable device circuits
Flexible display backplanes
Touch sensors for mobile devices
RFID tags and NFC antennas
Printed batteries for IoT devices
Performance Priorities: Cost efficiency, manufacturing scalability, adequate reliability for consumer expectations (typically 2-5 year product life).
Home and Domestic Robotics (Category 4)
Category 4 addresses emerging applications in home robotics and automated domestic systems. These applications combine consumer product expectations with safety requirements for human interaction.
Typical Applications:
Robot vacuum sensor arrays
Smart home environmental sensors
Automated pet care devices
Personal assistance robots
Home security sensor networks
Performance Priorities: Human safety in close proximity, reliable operation in home environments, dust and moisture resistance.
Industrial and Commercial Controls (Category 5)
Category 5 covers industrial applications where printed electronics enable distributed sensing, flexible controls, and harsh environment operation. These applications typically require longer service lives than consumer products and may face chemical exposure or extreme temperatures.
Typical Applications:
Manufacturing process sensors
Industrial equipment HMIs
Environmental monitoring systems
Asset tracking and identification
Condition monitoring for predictive maintenance
Performance Priorities: Chemical resistance, extended operating temperature range, reliability in industrial environments, electromagnetic compatibility.
Medical Applications (Category 6)
Category 6 addresses medical applications with their unique regulatory requirements and biocompatibility considerations. Medical printed electronics span from single-use diagnostic devices to long-term implantables.
Typical Applications:
Disposable diagnostic test strips
Wearable patient monitoring patches
Smart wound dressings
Drug delivery patches
Prosthetic sensor interfaces
Performance Priorities: Biocompatibility, sterilization compatibility, regulatory compliance (FDA, CE marking), reliability for patient safety.
Military Applications (Category 7)
Category 7 encompasses military and defense applications where printed electronics must operate in the most demanding environments while meeting strict military specifications.
Category 8 covers printed electronics integrated into building materials and architectural elements. These applications require exceptional service life measured in decades rather than years.
Typical Applications:
Smart windows with integrated sensors
Building envelope monitoring
Integrated lighting controls
Structural strain monitoring
HVAC zone sensors
Performance Priorities: 20+ year service life, UV stability, moisture resistance, integration with construction materials.
Smart Packaging Applications (Category 9)
Category 9 addresses the rapidly growing smart packaging market where printed electronics adds intelligence to product packaging. Cost constraints are typically severe, and many applications are single-use.
Category 10 covers printed electronics for electrical grid monitoring and control. These applications face outdoor exposure and must interface reliably with electrical infrastructure.
Typical Applications:
Power line monitoring sensors
Transformer health sensors
Solar panel monitoring
Grid-connected storage monitoring
Demand response systems
Performance Priorities: Outdoor durability, electrical safety, long service life, electromagnetic compatibility with grid systems.
Future Applications (Category 11)
Category 11 provides a placeholder for emerging applications that don’t fit existing categories. As printed electronics technology evolves, new market segments will emerge that require their own classification criteria.
IPC-6901 Level Classification System
Beyond market categories, IPC-6901 establishes a level classification system that defines the complexity and integration state of printed electronics assemblies. This four-level system applies to both fully printed electronics and Flexible Hybrid Electronics (FHE).
Level Classification Overview
Level
Assembly Type
Description
1
Passive Components
Basic printed elements (resistors, capacitors, antennas)
2
Active Components
Printed elements with active function (transistors, diodes)
Level 1 covers the most basic printed electronics elements that provide passive electrical functions. These components form the building blocks for more complex assemblies.
Printed Passive Components:
Printed resistors
Printed capacitors
Printed inductors
Printed antennas and RFID coils
Printed interconnects and traces
FHE Passive Components:
Hybrid circuits with printed passives and conventional interconnects
Printed antennas with conventional matching networks
Sensor electrodes with printed conductors
Level 2: Printed and FHE Active Components
Level 2 encompasses printed electronics with active device functionality. These components can amplify, switch, or otherwise actively process signals.
Printed Active Components:
Printed thin-film transistors (TFTs)
Printed diodes
Printed photodetectors
Organic LEDs (OLEDs)
Electrochromic displays
FHE Active Components:
Hybrid circuits combining printed elements with conventional ICs
Printed sensor arrays with conventional signal processing
Flexible circuits with attached silicon chips
Level 3: Printed and FHE Modules
Level 3 covers integrated subsystems that combine multiple components into functional modules. Modules provide defined functionality but are not complete end products.
Printed Modules:
Printed sensor modules with integrated processing
Display modules with driver circuitry
Printed battery systems with management circuits
Communication modules with antenna and logic
FHE Modules:
Sensor systems combining printed sensors with conventional MCUs
Power management modules with printed energy harvesting
Wireless modules integrating printed antennas with conventional RF ICs
Level 4: Printed and FHE Final Products
Level 4 represents complete products ready for end-user deployment. Final products incorporate all necessary functionality including power, sensing, processing, and interfaces.
Printed Final Products:
Complete wearable health monitors
Standalone smart packaging solutions
Integrated sensor systems with wireless communication
Consumer electronic devices
FHE Final Products:
Medical patches with complete diagnostic capability
Automotive sensor assemblies ready for vehicle integration
Industrial monitoring systems for direct deployment
Flexible Hybrid Electronics in IPC-6901
IPC-6901 explicitly addresses Flexible Hybrid Electronics (FHE), recognizing that most commercial printed electronics products combine printed and conventional components. The standard includes FHE definitions and applies classification systems equally to pure printed electronics and hybrid approaches.
Key FHE Terms Defined in IPC-6901
Term
Definition
Flexible Hybrid Electronics
Electronics combining printed/flexible elements with conventional components
Front-End Assembly
Printing and deposition processes for creating circuitry
Back-End Assembly
Component attachment and final integration processes
Post Processing
Treatment after printing (sintering, curing, encapsulation)
Stretchable Electronics
Circuits designed to accommodate mechanical stretching
Wearable Electronics
Electronics designed for body-worn applications
Understanding these distinctions matters because FHE products often face different testing requirements than fully printed alternatives. The combination of printed and conventional elements creates unique reliability considerations at material interfaces.
Performance Criteria and Testing Methods
IPC-6901 establishes categories of performance criteria applicable to printed electronics, with specific tests selected based on market category and assembly level. The standard provides a framework rather than mandating specific tests, allowing flexibility for application-specific requirements.
Performance Criteria Categories
Category
Scope
Example Tests
Chemical Resistance
Exposure to chemicals, solvents, cleaning agents
Solvent resistance, chemical spot tests
Electrical
Functional electrical performance
Continuity, insulation resistance, high-pot
Mechanical
Physical durability and integrity
Flexure, drop, vibration, adhesion
Operation
In-use functional performance
Burn-in, functional test, environmental
Reliability
Long-term performance stability
Accelerated aging, HALT/HASS
Safety
Human and environmental safety
Biocompatibility, flammability, toxicity
Visual
Cosmetic appearance criteria
Defect inspection, surface quality
Chemical Resistance Testing
Chemical resistance testing verifies that printed electronics assemblies can withstand exposure to chemicals encountered during manufacturing, assembly, and end use. For medical applications, this includes sterilization chemicals. For industrial applications, process chemicals and cleaning solvents are relevant.
Electrical Testing
Electrical testing confirms that printed circuits meet functional requirements. Unlike traditional PCBs, printed electronics often exhibit higher resistance values and greater variability, requiring adapted test limits and methods.
Mechanical testing addresses the unique flexibility and conformability characteristics of printed electronics. Standard rigid PCB mechanical tests are often inappropriate for flexible substrates.
Key Mechanical Tests:
Flexure testing (static and dynamic bending)
Drop testing
Vibration testing
Adhesion testing (conductor to substrate)
Abrasion resistance
Crease resistance
Reliability Testing
Reliability testing accelerates aging mechanisms to predict long-term performance. Test conditions should reflect the actual use environment defined by the market category.
Common Reliability Tests:
Temperature cycling
Humidity exposure (steady-state and cycling)
Combined temperature/humidity/bias
Mechanical fatigue (repeated flexing)
UV exposure (for outdoor applications)
Safety Testing
Safety testing requirements vary significantly by market category. Medical and food-contact applications require biocompatibility and toxicity testing. Consumer products require flammability testing. All products must meet applicable regulatory safety requirements.
Quality Assurance Provisions in IPC-6901
IPC-6901 establishes quality assurance requirements adapted to printed electronics manufacturing. These provisions address the unique characteristics of printed electronics while maintaining compatibility with established quality systems.
Quality System Requirements
Requirement
Description
Responsibility for Inspection
Defines who performs inspection activities
Responsibility for Compliance
Establishes compliance accountability
Quality Assurance Program
Requires documented quality program
Test Equipment
Calibration and maintenance requirements
Sample Preparation
Standard methods for test sample preparation
Laboratory Conditions
Environmental requirements for testing
Qualification vs. Conformance Testing
IPC-6901 distinguishes between qualification inspection (initial product validation) and quality conformance inspection (ongoing production verification).
Qualification Inspection:
Comprehensive testing of initial production
Validates that design meets performance requirements
Typically extensive testing of limited samples
Required before production release
Quality Conformance Inspection:
Ongoing verification during production
Sampling-based inspection of production lots
Primary and secondary inspection provisions
Statistical process control options
Statistical Process Control
IPC-6901 supports statistical process control (SPC) as an alternative to end-of-line inspection. When manufacturers demonstrate process capability through SPC, the standard allows reduced quality conformance testing frequency.
Using IPC-6901 Classification in Practice
Applying IPC-6901 requires determining both market category and assembly level for your product. This dual classification drives performance requirements and testing strategy.
Classification Decision Process
Step 1: Determine Market Category Identify the primary end-use market for your product. If multiple markets apply, use the most demanding category.
Step 2: Determine Assembly Level Assess whether your product is a component (Level 1-2), module (Level 3), or final product (Level 4).
Step 3: Identify Performance Requirements Based on category and level, determine applicable performance criteria.
Step 4: Select Test Methods Choose appropriate test methods from IPC-6901 framework or industry-specific standards.
Step 5: Document in Procurement Include classification and requirements in procurement documentation.
Example Classification
Consider a printed glucose sensor patch for diabetic monitoring:
IPC-6901 and Related Printed Electronics Standards
IPC-6901 functions within a broader ecosystem of printed electronics standards. Understanding these relationships helps engineers apply the complete framework effectively.
Printed Electronics Standards Ecosystem
Standard
Title
Relationship to IPC-6901
IPC-2291
Design Guideline for Printed Electronics
Design guidance for PE products
IPC-2292
Design Standard for PE on Flexible Substrates
Detailed design requirements
IPC-4591
Requirements for Functional Conductive Materials
Ink and paste specifications
IPC-4921
Requirements for PE Base Materials
Substrate specifications
IPC-6902
Qualification and Performance Specification
Detailed qualification requirements
IPC-6903
Terms and Definitions for PE
Common terminology
IPC-9204
Flexibility and Stretchability Testing
Test methods for flex/stretch
IPC-6901 vs IPC-6902
IPC-6901 establishes classification categories and general performance frameworks. IPC-6902 provides detailed qualification and performance specifications for products classified using IPC-6901. Think of IPC-6901 as answering “what category is my product?” while IPC-6902 answers “exactly what tests must it pass?”
What is the difference between IPC-6901 and IPC-6902?
IPC-6901 establishes the classification system for printed electronics, defining market categories and assembly levels. It provides a framework for identifying what performance criteria apply to different product types. IPC-6902 is the companion qualification and performance specification that provides detailed test requirements and acceptance criteria for products classified using IPC-6901. You typically use IPC-6901 first to classify your product, then reference IPC-6902 for specific qualification requirements.
How do I classify a product that serves multiple markets?
When a printed electronics product serves multiple market categories, IPC-6901 recommends using the most demanding category to establish performance requirements. For example, a sensor used in both consumer wearables (Category 3) and medical monitoring (Category 6) should be designed and tested to Category 6 medical requirements. This ensures the product meets the highest applicable standards.
Does IPC-6901 apply to traditional flexible circuits?
IPC-6901 specifically addresses printed electronics and Flexible Hybrid Electronics (FHE), not traditional etched flexible circuits. Traditional flex circuits are covered by IPC-6013 (Qualification and Performance Specification for Flexible Printed Boards). However, hybrid products combining printed elements with traditional flex circuit construction may reference both standards.
What testing is required for IPC-6901 compliance?
IPC-6901 establishes performance criteria categories but does not mandate specific tests for all products. The appropriate tests depend on market category and assembly level. The standard provides a framework that users adapt to their specific application. For detailed test requirements, reference IPC-6902 and application-specific standards (e.g., ISO 10993 for medical biocompatibility).
How does IPC-6901 address emerging applications?
IPC-6901 includes Category 11 (Future) specifically for emerging applications that don’t fit existing market categories. As new applications develop, users can apply the general framework of performance criteria categories while the standard evolves to add specific guidance. IPC encourages users to submit information on new applications to help guide future standard revisions.
Implementing IPC-6901 in Your Organization
Successfully implementing IPC-6901 requires coordination across product development, quality, and supply chain functions.
Design Engineering
Determine market category early in product development
Use category to establish design requirements
Reference level classification for appropriate complexity
Document classification in design specifications
Quality Engineering
Develop test plans based on IPC-6901 performance criteria
Establish qualification protocols aligned with classification
Implement conformance testing appropriate to production
Consider SPC for process-capable operations
Procurement
Include IPC-6901 classification in supplier requirements
Specify category and level in purchase orders
Require supplier compliance with applicable criteria
Establish incoming inspection based on classification
Conclusion
IPC-6901 provides the essential classification framework for printed electronics products, enabling engineers to systematically identify performance requirements based on application and assembly complexity. The standard’s dual classification system—eleven market categories and four assembly levels—creates a structured approach to product development that ensures appropriate reliability and performance for each application.
For printed electronics engineers, understanding IPC-6901 is fundamental to successful product development. Whether you’re designing a medical diagnostic patch, an automotive interior sensor, or a smart packaging indicator, IPC-6901 helps you identify what matters for your specific application. Combined with companion standards like IPC-6902 for detailed qualification requirements and IPC-4591/IPC-4921 for materials, IPC-6901 forms the backbone of the printed electronics standards ecosystem.
The printed electronics industry continues to evolve rapidly, with new applications emerging regularly. IPC-6901’s framework provides stability for established applications while accommodating innovation through its Category 11 provisions for future applications. As you develop printed electronics products, start with IPC-6901 classification to establish the foundation for successful product development.
Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
